ENERGY MATERIALS COORDINATING COMMITTEE (EMaCC)

DOE/SC-0077

ENERGY MATERIALSCOORDINATING COMMITTEE

(EMaCC)Fiscal Year 2002

August 8, 2003

Annual Technical Report

U.S. Department of EnergyOffice of Science

Office of Basic Energy SciencesDivision of Materials Sciences and Engineering

Washington, DC 20585-1290

Table of Contents

i

TABLE OF CONTENTS

Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Energy Materials Coordinating Committee Membership List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Organization of the Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7FY 2002 Budget Summary of DOE Materials Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Distribution of Funds by Office . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PROGRAM DESCRIPTIONS

OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

OFFICE OF BUILDING TECHNOLOGY, STATE AND COMMUNITY PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DISTRIBUTED ENERGY & ELECTRICITY RELIABILITY PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16High Temperature Superconductivity for Electric Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

FREEDOMCAR & VEHICLE TECHNOLOGIES PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Materials Technologies Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Automotive Propulsion Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Automotive Lightweight Vehicle Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Heavy Vehicle Propulsion System Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31High Strength Weight Reduction Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37High Temperature Materials Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

GEOTHERMAL TECHNOLOGIES PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Geothermal Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

HYDROGEN, FUEL CELLS & INFRASTRUCTURE TECHNOLOGIES PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Fuel Cells Materials Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

INDUSTRIAL TECHNOLOGIES PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Aluminum Vision Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Glass Industry of the Future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Forest and Paper Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Metal Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Industrial Materials for the Future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

SOLAR ENERGY TECHNOLOGY PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74National Photovoltaics Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Financial Assistance Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Inventions & Innovation (I&I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81National Industrial Competitiveness Through Energy, Environment and Economics (NICE3) . . . . . . . . . . . . . . . . 89

Table of Contents

ii

TABLE OF CONTENTS (continued)

Page

OFFICE OF SCIENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Office of Basic Energy Sciences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Division of Materials Sciences and Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Office of Advanced Scientific Computing Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Division of Technology Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Laboratory Technology Research Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Small Business Innovation Research Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Small Business Technology Transfer Research Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Office of Fusion Energy Sciences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

OFFICE OF ENVIRONMENTAL MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Office of Space and Defense Power Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Space and National Security Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Office of Technology and International Cooperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Nuclear Energy Plant Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Nuclear Energy Research Initiative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141International Nuclear Energy Research Initiative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

NATIONAL NUCLEAR SECURITY ADMINISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Office of Naval Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Office of Defense Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

The Weapons Research, Development and Test Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Sandia National Laboratories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Los Alamos National Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164Lawrence Livermore National Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

OFFICE OF CIVILIAN RADIOACTIVE WASTE MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

OFFICE OF FOSSIL ENERGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Office of Advanced Research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Fossil Energy Advanced Research Materials Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Advanced Metallurgical Processes Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

DIRECTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

LIST OF TABLES

Table 1 Energy Materials Coordinating Committee Membership List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Table 2 Distribution of Funds by Office . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Introduction

1

INTRODUCTION

The DOE Energy Materials Coordinating Committee (EMaCC) serves primarily to enhance coordination among theDepartment's materials programs and to further effective use of materials expertise within the Department. These functionsare accomplished through the exchange of budgetary and planning information among program managers and throughtechnical meetings/workshops on selected topics involving both DOE and major contractors. In addition, EMaCC assists inobtaining materials-related inputs for both intra- and interagency compilations.

Topical subcommittees of the EMaCC are responsible for conducting seminars and otherwise facilitating information flowbetween DOE organizational units in materials areas of particular importance to the Department. The EMaCC Terms ofReference were recently modified and developed into a Charter that was approved on June 5, 2003. As a result of thisreorganization, the existing subcommittees were disbanded and new subcommittees are being formed. The EMaCCCharter and the memorandum approving it are presented in the Appendix of this report. Membership in the EMaCC is open to any Department organizational unit; participants are appointed by Division or OfficeDirectors. The current active membership is listed on pages 4-6.

Four meetings were scheduled for 2002-2003. The dates and minutes from the meetings are as follows:

OCTOBER 17, 2002, GERMANTOWN

Chairman, Dr. Udaya Rao, opened the meeting by having the participants introduce themselves.

Robert Gottschall (BES) presented the format and expected outcome of the Workshop on Basic Research Needs toAssure a Secure Energy Future. This workshop was held October 21-25, 2002, by a sub-panel of the Basic EnergySciences Advisory Committee (BESAC). The outcome of the workshop is to be a list of proposed research directions andsupporting statement for each entry (including impact and time scale) that BESAC as a whole will consider. A preliminarypresentation will be made to BESAC at its November 5-6, 2002, meeting. The full report will not be available until it iscompleted and accepted by BESAC. This may occur at the February 2003 BESAC meeting. The agenda for theBESAC November 5-6, 2002, BESAC meeting may be found at (http://www.science.doe.gov/production/bes/BESAC/nov02agenda.pdf). Richard Smith (NSF) discussed the NSF Engineering Directorate Working Group on Energy, which has the objectiveto “identify (interagency) research opportunities that comprise a broader vision for fundamental energy research.” Thegroup clearly intends to seek both new opportunities and greater interagency coordination. The speaker’s PowerPointpresentation is available subject to the proviso that it is at an early stage and changes are to be expected. Interestedparties should contact D. Koelling.

The minutes of the July 16, 2002, meeting were approved. It was moved by R. Gottschall that the slate of officers beelected unanimously. The motion was seconded by C. Sorrell and the motion carried. Accordingly, the officers for 2003 areD. Koelling, chair, and L. Wilson, secretary. Possible dates for the meeting in January, 2003, were discussed. A more orless traditional choice of January 14 appeared to have significant conflicts. Members were asked to advise Koelling and/orWilson of their availability. The meeting was then adjourned.

Parenthetically, there appeared to be good informal discussion both before and after the meeting. CALENDAR ITEMS

Oct. 21-25, 2002 Workshop on Basic Research Needs to Assure a Secure Energy Future, Gaithersburg, MD, contactSharon Long

Nov. 5-6, 2002 Basic Energy Sciences Advisory Committee meeting, Gaithersburg, MD, contact Sharon Long

Feb. 25, 2003 Basic Energy Sciences Advisory Committee meeting, Gaithersburg, MD, contact Sharon Long

Feb. 26-28, 2003 DOE Nanoscale Science Centers Workshop, Renaissance Hotel, Washington, D.C. Seehttp://www.ornl.gov/doensrcworkshop/

Introduction

2

LIST OF PARTICIPANTS

Altaf Carim SC-13 [email protected] Chen SC-13 [email protected] Gottschall SC-13 [email protected] Kini SC-13 [email protected] Koelling SC-13 [email protected] Kung SC-13 [email protected] Rao FE/NETL [email protected] N. Smith NSF/ENG/CTS [email protected] Sorrell EE-2F [email protected] Wilson FE/NETL [email protected] Zhu SC-13 [email protected]

JANUARY 21, 2003, FORRESTAL BUILDING

EMaCC Chair, Dale Koelling, conducted the meeting; minutes by Lane Wilson, Executive Secretary.

Robert Budnitz, on assignment from LLNL to the Office of Civilian Radioactive Waste Management (RW-40E), gave anoverview of the Yucca Mountain radioactive waste (RW) repository. He presented the environmental and safety constraintsimposed on the materials systems for RW storage. He stressed that the current design and materials plan can beimplemented with a large margin of safety under applicable regulations. The purpose of the science and technologyprogram that is being initiated by RW is to explore opportunities to lower the costs of the facility through possible materialsimprovements.

All parts in the storage tunnels are non-mechanical. Some of the relevant parts are the “drift shield”, which diverts anymoisture that drifts into the tunnel and the “drift invert” which would collect any moisture away from the storage cask andprovide a further barrier to ground penetration. The drift invert also performs the structural task of supporting the storagecasks. The parts are all made of expensive high grade materials like NiCr superalloys with well-characterized mechanicalloading and chemical sorption properties.

Research opportunities may possibly involve surface coatings or non-metallic materials systems. The first casks arescheduled to be loaded into a tunnel at the Yucca Mountain (YM) site in 2010 and the last one in 2034. In order for any newmaterials to be employed during the later years of the site loading, they will need life cycle validation in the time range of2010-2020.

There is also a performance confirmation program involving the NRC for the first 100 years of ventilated use before thetunnels are sealed. This could possibly make use of remote sensor R&D.

William Lake (RW-30E) presented the materials needs for the casks used to seal the RW. The casks will be moved byground transportation to the YM site. The current design was certified by the NRC 40 years ago for adequate safety but likethe materials in the YM facility, there are opportunities in materials design to reduce the cost while maintaining performancein areas such as structural containment, radiation shielding, nuclear sub-criticality, and heat dissipation. There are alsoconsiderations for weight, impact protection, and personnel barriers.

CALENDAR ITEMS

June 3-5 Materials and Engineering Physics on-site review at Argonne National LaboratoryApril 15 Next EMaCC Meeting

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APRIL 15, 2003, GERMANTOWN

Dale Koelling, EMaCC Chair, conducted the meeting and minutes were taken by Lane Wilson, Executive Secretary.

Pat Dehmer reported on the BES/BESAC Workshop on “Basic Research Needs to Assure a Secure Energy Future.” It washeld October 21-25, 2002. The workshop report will function as a “guiding force” in future DOE planning. Thirty sevenproposed research directions were put forth. Ten basic research directions were identified and will be explored withsubsequent workshops. For example, the direction “Research Towards the Hydrogen Economy” will be examined in a mid-May workshop. Another direction “Materials Research to Transcend Energy Barriers” reflects the fact that about half theproposed research directions had materials issues as technology barriers.

The Workshop Summary emphasized that the problems will require interdisciplinary non-traditional research structures withcoordinated integration of the necessary skill sets.

Teresa Fryberger of the Office of Biological and Environmental Research (BER) reported on the work of the EnvironmentalRemediation Sciences group. The research supports the goal of converting waste and contaminants into a more stableform. The major efforts involve the Natural and Accelerated Bioremediation Program (NABIR) and the EnvironmentalManagement Science Program (EMSP) with research facilities of the Environmental Molecular Sciences Laboratory (EMSLat PNNL) and the Savannah River Ecology Laboratory (SREL).

A discussion followed contrasting the remediation efforts of BER with issues presented at the last EMaCC meeting by BobBudnitz concerning radioactive waste management at the Yucca Mountain repository. An EMaCC topical subgroup wassuggested and a steering committee of R. Budnitz, T. Fryberger, T. Kiess and R. Gottschall was formed to report back onestablishing the sub-group.

The Terms of Reference document (dated 8/24/1993) has been located and will be discussed at the next EMaCC meeting.

A request was made for a web-based archival system of EMaCC reports.

LIST OF PARTICIPANTS

Bob BudnitzYok ChenPat DehmerSara DillichTeresa Fryberger

Bob GottschallJim HorwitzHelen KerchTom KiessDale Koelling

Harriet KungBill OosterhuisMike SoboroffLane WilsonJane Zhu

JULY 15, 2003, FORRESTAL BUILDING

Minutes of the July 2003 EMaCC meeting will be published in the FY03 EMaCC Annual Technical Report.

The EMaCC reports to the Director of the Office of Science in his or her capacity as overseer of the technical programs ofthe Department. This annual technical report is mandated by the EMaCC Charter (see Appendix). This report summarizesEMaCC activities for FY 2002 and describes the materials research programs of various offices and divisions within theDepartment.

The EMaCC Chair for FY 2002 was Dr. Udaya Rao. The compilation of this report was performed by Dr. Lane Wilson,EMaCC Executive Secretary for FY 2003, with the assistance of the RAND Corporation. Financial support was provided bythe Industrial Materials for the Future program of the Industrial Technologies Program and by the Office of Basic EnergySciences.

Dr. Dale KoellingOffice of ScienceEMaCC Chair, FY 2003

Membership List

4

TABLE 1ENERGY MATERIALS COORDINATING COMMITTEE MEMBERSHIP LIST

ORGANIZATION REPRESENTATIVE PHONE NO.

ENERGY EFFICIENCY AND RENEWABLE ENERGY

Building Technologies Marc Lafrance, EE-2J 202-586-9142

Distributed Energy & Electricity Reliability

High Temperature Superconductivity James Daley, EE-2D 202-586-1165

FreedomCAR & Vehicle Technologies

Automotive Lightweight Vehicle MaterialsHeavy Vehicle Materials Technologies

Joseph Carpenter, EE-2GSidney Diamond, EE-2G

202-586-1022202-586-8032

Geothermal Technologies

Geothermal Materials Raymond LaSala, EE-2C 202-586-4198

Hydrogen, Fuel Cells & Infrastructure Technologies

Fuel Cell Materials

Nancy Garland, EE-2HJoAnn Milliken, EE-2H

202-586-5673202-586-2480

Industrial Technologies

Materials and Materials ProcessesMaterials Liaison

Sara Dillich, EE-2FCharlie Sorrell, EE-2F

202-586-7925202-586-1514

Solar Energy Technology

National Photovoltaic Program Richard King, EE-2ARay Sutula, EE-2A

202-586-1693202-586-8064

Membership List


5

SCIENCE

Basic Energy Sciences

Materials Sciences and Engineering

Metals, Ceramics and Engineering

Condensed Matter Physics and MaterialsChemistry

Chemical Sciences, Geosciences and Biosciences

Pat Dehmer, SC-10Iran L. Thomas, SC-13Robert J. Gottschall, SC-13Yok Chen, SC-13Helen Kerch, SC-13W. Oosterhuis, SC-13Jerry Smith, SC-13Richard Kelly, SC-13Manfred Leiser, SC-13Matesh (Mat) Varma, SC-13Altaf Carim, SC-13

Arivinda M. Kini, SC-13 Pedro Montano, SC-13

Nick Woodward, SC-14

301-903-3081301-903-3427301-903-3428301-903-3428301-903-3428301-903-3426301-903-3426301-903-3426301-903-3426301-903-3209301-903-4895301-903-3565301-903-2347301-903-4061

Advanced Scientific Computing Research

Technology Research Samuel J. Barish, SC-32 301-903-2917

Fusion Energy Sciences

Facilities and Enabling Technologies Sam Berk, SC-52 301-903-4171

Biological and Environmental Research

Medical Sciences Larry James, SC-73 301-903-7481

ENVIRONMENTAL RESTORATION AND WASTE MANAGEMENT

Integration and Disposition

Technical Program Integration Doug Tonkay, EM-22 301-903-7212

Science and Technology

Basic and Applied Research Chet Miller, EM-52 202-586-3952

Membership List


6

NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY

Technology and International Cooperation Steve Sherman, NE-20 301-903-2714

Nuclear Facilities Management John Warren, NE-40Bob Lange, NE-40

301-903-6491301-903-2915

Space and Defense Power Systems John Dowicki, NE-50 301-903-7729

NATIONAL NUCLEAR SECURITY ADMINISTRATION

Naval Reactors David I. Curtis, NR-1 202-781-6141

Defense Programs

Defense Science Bharat Agrawal, NA-113-2 301-903-2057

CIVILIAN RADIOACTIVE WASTE MANAGEMENT

Waste Acceptance and Transportation Jim Carlson, RW-40 202-586-5321

FOSSIL ENERGY

Advanced Research Fred M. Glaser, FE-25 301-903-2786

Organization of the Report

7

ORGANIZATION OF THE REPORT

The FY 2002 budget summary for DOE Materials Activities is presented on page 8. The distribution of these funds betweenDOE laboratories, private industry, academia and other organizations is presented in tabular form on page 10.

Following the budget summary is a set of detailed program descriptions for the FY 2002 DOE Materials activities. Thesedescriptions are presented according to the organizational structure of the Department. A mission statement, a budgetsummary listing the project titles and FY 2002 funding, and detailed project summaries are presented for each AssistantSecretary office, the Office of Science, and the National Nuclear Security Administration. The project summaries alsoprovide DOE, laboratory, academic and industrial contacts for each project, as appropriate.

FY 2002 Budget Summary of DOE Materials Activities

8

FY 2002 BUDGET SUMMARY OF DOE MATERIALS ACTIVITIES

These budget numbers represent materials-related activities only. They do not include those portions of program budgetswhich are not materials related.

FY 2002

OFFICE OF BUILDING TECHNOLOGY, STATE AND COMMUNITY PROGRAMS $2,989,000

DISTRIBUTED ENERGY & ELECTRICITY RELIABILITY PROGRAM $32,000,000High Temperature Superconductivity for Electric Systems 32,000,000

FREEDOMCAR & VEHICLE TECHNOLOGIES PROGRAM $39,009,000Materials Technologies Program 39,009,000

Automotive Propulsion Materials 2,845,000Automotive Lightweight Vehicle Materials 15,750,000Heavy Vehicle Propulsion System Materials 4,944,000High Strength Weight Reduction Materials 9,870,000High Temperature Materials Laboratory 5,600,000

GEOTHERMAL TECHNOLOGIES PROGRAM $395,000Geothermal Materials 395,000

HYDROGEN, FUEL CELLS AND INFRASTRUCTURE TECHNOLOGIES PROGRAM $815,000Fuel Cells Materials Program 815,000

INDUSTRIAL TECHNOLOGIES PROGRAM $28,167,398Aluminum Vision Team 10,874,792Glass Industry of the Future 200,000Forest and Paper Products 1,950,792Metal Casting 1,403,000Industrial Materials for the Future 13,738,814

SOLAR ENERGY TECHNOLOGY PROGRAM $36,178,000National Photovoltaics Program 36,178,000

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM $4,777,020Financial Assistance Program 4,777,020

Inventions & Innovation (I&I) 2,175,382National Industrial Competitiveness Through Energy, Environment and Economics (NICE3) 2,601,638

OFFICE OF SCIENCE $539,912,655Office of Basic Energy Sciences 490,258,000

Division of Materials Sciences and Engineering 490,258,000Office of Advanced Scientific Computer Research 41,254,655

Division of Technology Research 41,254,655Laboratory Technology Research Program 1,545,000Small Business Innovation Research Program 37,722,980Small Business Technology Transfer Research Program 1,986,675

Office of Fusion Energy Sciences 8,400,000

OFFICE OF ENVIRONMENTAL MANAGEMENT $3,602,996


1This excludes $51.7 million for the cost of irradiation testing in the Advanced Test Reactor (ATR).

9

FY 2002 BUDGET SUMMARY OF DOE MATERIALS ACTIVITIES (continued)

FY 2002

OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY $12,730,821Office of Space and Defense Power Systems 3,781,000

Space and National Security Programs 3,781,000Office of Technology and International Cooperation 8,949,821

Nuclear Energy Plant Optimization 3,555,000Nuclear Energy Research Initiative 4,569,821International Nuclear Energy Research Initiative 825,000

NATIONAL NUCLEAR SECURITY ADMINISTRATION $114,492,000 Office of Naval Reactors 79,200,0001

Office of Defense Programs 14,486,000 The Weapons Research, Development and Test Program 14,486,000

Sandia National Laboratories 14,486,000 Los Alamos National Laboratory 15,223,000

Lawrence Livermore National Laboratory 5,583,000

OFFICE OF CIVILIAN RADIOACTIVE WASTE MANAGEMENT $30,540,000

OFFICE OF FOSSIL ENERGY $10,343,999 Office of Advanced Research 10,343,999

Fossil Energy Advanced Research Materials Program 6,745,999 Advanced Metallurgical Processes Program 3,598,000

TOTAL $855,952,889


10

The distribution of these funds between DOE laboratories, private industry, academia and other organizations is listedbelow.

TABLE 2DISTRIBUTION OF FUNDS BY OFFICE

Office DOELaboratories

Private Industry Academia Other Total

Building Technologies Program $1,880,000 $1,034,000 $75,000 $0 $2,989,000

Distributed Energy & ElectricityReliability Program $12,128,000 $16,545,000 $3,000,000 $327,000 $32,000,000

FreedomCAR & VehicleTechnologies $24,413,000 $11,161,000 $2,145,000 $1,290,000 $39,009,000

Geothermal TechnologiesProgram $395,000 $0 $0 $0 $395,000

Hydrogen, Fuel Cells &Infrastructure TechnologiesProgram

$600,000 $0 $215,000 $0 $815,000

Industrial TechnologiesProgram $13,358,792 $10,105,792 $4,430,814 $272,000 $28,167,398

Solar Energy TechnologyProgram $36,178,000 $0 $0 $0 $36,178,000

Weatherization &Intergovernmental Program $0 $4,537,142 $239,878 $0 $4,777,020

Office of Science $431,470,000 $39,709,655 $67,710,000 $1,023,000 $539,912,655

Office of EnvironmentalManagement $2,225,996 $0 $1,377,000 $0 $3,602,996

Office of Nuclear Energy,Science and Technology $10,193,398 $1,510,000 $827,423 $200,000 $12,730,821

National Nuclear SecurityAdministration $114,492,000 $0 $0 $0 $114,492,000

Office of Civilian RadioactiveWaste Management $30,540,000 $0 $0 $0 $30,540,000

Office of Fossil Energy $8,943,000 $200,999 $780,000 $420,000 $10,343,999

TOTALS $686,817,186 $84,803,588 $80,800,115 $3,532,000 $855,952,889

Office of Energy Efficiency and Renewable Energy

11

OFFICE OF ENERGY EFFICIENCY AND RENEWABLE ENERGY

The Office of Energy Efficiency and Renewable Energy (EERE) mission is to strengthen America's energy security,environmental quality and economic vitality in public-private partnerships that:

• Enhance energy efficiency and productivity• Bring clean, reliable and affordable energy technologies to the marketplace• Make a difference in the everyday lives of Americans by enhancing their energy choices and their quality of life

EERE's program activities are conducted in partnership with the private sector, state and local government, DOE nationallaboratories, and universities. In July 2002, EERE reorganized to strengthen its focus on programs and these partnerships.

In contrast to the previous organization into five energy sectors—industry, transportation, buildings, power and Federalagencies—EERE is now organized around eleven energy programs:

• Biomass Program• Building Technologies Program• Distributed Energy & Electricity Reliability Program• Federal Energy Management Program• FreedomCAR & Vehicle Technologies Program• Geothermal Technologies Program• Hydrogen, Fuel Cells & Infrastructure Technologies Program• Industrial Technologies Program• Solar Energy Technology Program• Weatherization & Intergovernmental Program• Wind & Hydropower Technologies Program

Several of these programs sponsor materials research and the breadth of the EERE materials research is substantial,including research on metals, ceramics, polymers, magnetic materials, superconductors, composites, coatings, nanoscalematerials, advanced forming, welding and joining, corrosion, erosion, wear and other areas.

Office of Building Technology, State and Community Programs

12

OFFICE OF BUILDING TECHNOLOGY, STATE AND COMMUNITY PROGRAMS

FY 2002

OFFICE OF BUILDING TECHNOLOGIES - GRAND TOTAL $2,989,000

OFFICE OF BUILDING RESEARCH AND STANDARDS $2,989,000

MATERIALS PROPERTIES, BEHAVIOR, CHARACTERIZATION OR TESTING 1,305,000

Non-HCFC Closed-Cell Foam Insulation 150,000Hygrothermal Material Property Measurements & Modeling Upgrades and Applications 855,000Insulation Materials Performance & Application 150,000Sub-Ambient Pipe Insulation Materials and Systems 75,000Floor Tile with Phase Change Materials 75,000

FENESTRATION MATERIALS DEVELOPMENT $1,684,000

Development of Electrochromic Materials and Coatings 1,486,000Development of Aerogel Materials for R10/ inch Transparent Window Insulation 198,000


13

OFFICE OF BUILDING TECHNOLOGY, STATE AND COMMUNITY PROGRAMS

OFFICE OF BUILDING RESEARCH AND STANDARDS

The goal of the program is to develop advanced windows, new building materials and building envelope systems that cancontribute to the DOE energy efficiency goal of constructing zero energy buildings. These activities will result in building systemsthat consume significantly less energy while drastically reducing peak electricity demand.

The program objectives are:

1) The development of Advanced Windows that have highly insulating properties, that offer dynamic solar heat gain control,and have very low solar heat gain coefficients;

2) Develop moisture design guidelines for all regions of the country using fundamental material properties and advancedmodeling to ensure that building envelope performance can be increased without moisture and mold problems;

3) Develop the scientific and engineering tools for development, demonstration and production of more energy efficient, durableaffordable and sustainable building envelope system technologies;

4) Identify and develop new or improved insulation and other building materials; 5) Develop and standardize laboratory methods for characterizing new and existing materials;6) Make recommendations on the effective use of building materials;7) Develop a fundamental understanding of the physics of heat, air, and moisture flow in advanced and conventional building

materials;8) Develop and standardize field and laboratory whole envelope system performance test protocols to stimulate development

and investment in energy efficient envelope technologies;9) Provide data developed for energy efficient building envelope and material technologies for inclusion into the Building Codes

and Standards.

The DOE contact is Marc LaFrance, (202) 586-9142

MATERIALS PROPERTIES, BEHAVIOR,CHARACTERIZATION OR TESTING

1. NON-HCFC CLOSED-CELL FOAM INSULATION$150,000DOE Contact: Marc LaFrance (202) 586-9142 ORNL Contact: Ken Wilkes (865) 574-5931

This project is for the development of foam insulationsthat use alternative blowing agents as drop-inreplacements for the CFC blowing agents that werepreviously used in the manufacture of foam insulationproducts and for the HCFC blowing agents that arecurrently being used. Prototype foam insulation boardsand refrigerator panels were sent to ORNL for testing andevaluation. Long-term tests are being conducted todetermine thermal properties and aging characteristics.Models are being developed for aging processes,including the effects of facing materials.

Keywords: CFC, Foam Insulation, InsulationSheathing, Roofs, HCFC, Refrigerators

2. HYGROTHERMAL PROPERTY MEASUREMENTS& MODELING UPGRADES AND APPLICATIONS$855,000DOE Contact: Marc LaFrance (202) 586-9142 ORNL Contact: Andre Desjarlais (865) 574-0022

The objective of this task is to measure the hygrothermalproperties of a broad range of building materials that arerequired for modeling of moisture transport in buildingenvelopes. Such property values are needed as inputs tomoisture simulation models and provide the link betweenthe models and large-scale experiments on moisturetransfer in building envelope components. The intent ofthe proposed work is to develop unique hygrothermal-durability modeling capability to permit prediction long-term performance of wall systems. The model, WUFI, is ajoint project with Germany. The model can bedownloaded for free in North America athttp://www.ornl.gov/ORNL/BTC/moisture/index.html. Themodel will be used to develop guidelines for moisturemanagement strategies for wall systems to meet userrequirements of long-term performance and durability forthe wide range of climate zones across North America.Properties that will be measured include sorption andsuction isotherms, vapor permeance, liquid diffusivity, airpermeability, specific heat, and thermal conductivity.Where applicable, the properties will be measured asfunctions of moisture content and temperature. Thelaboratory will support other research on measurements


14

and modeling of coupled heat, air, and moisture transferin building envelopes.

Keywords: Hygrothermal, Moisture, Building Materials,Heat-Air-Moisture, Properties

3. CONVENTIONAL MATERIALS PERFORMANCE$150,000DOE Contact: Marc LaFrance (202) 586-9142ORNL Contact: Ken Wilkes (865) 574-5931

This project is for the development of accurate andreproducible data for use by the building materialscommunity, improved test procedures to determine thethermal properties of existing, as well as advanced,insulations, interacting with the building materialsresearch community, manufacturers, trade associations,professional societies, compliance groups and localgovernment, and making and disseminatingrecommendations on appropriate usage of thermalinsulation to conserve energy.

Keywords: Insulation, Buildings

4. SUB-AMBIENT PIPE INSULATION MATERIALSAND SYSTEMS$75,000DOE Contact: Marc LaFrance (202) 586-9142ORNL Contact: Bill Miller (865) 574-2013

Pipe thermal insulations are rated by the thermalresistance as measured in pipe testing apparatus inconformance with ASTM C335. The scope of ASTMC335 limits its use to piping systems operating attemperatures above ambient. Numerous ASTM materialspecifications specify the use of these materials on pipesoperating below ambient conditions. There are no testmethods or test facilities available for undertaking thesemeasurements.

Pipe insulations applied to piping operating at sub-ambient conditions are also a major concern withinASHRAE. These insulation systems can have severemoisture-related problems due to the unidirectionalnature of their vapor drive. Attempts to address the rashof failures to these systems due to moisture ingressleading to loss in energy efficiency as well as mechanicalfailure are planned.

Keywords: Piping, Moisture, Insulation, Properties

5. PHASE CHANGE MATERIALS IN FLOOR TILESFOR THERMAL STORAGEDOE $75,000, Colorado State Univ. cost-sharing$18,000DOE Contact: Marc LaFrance (202) 586-9142 CSU Contact: Doug Hittle (970) 229-9403

Colorado State University received a competitivelyawarded project to develop a floor tile with phase changematerial incorporated into the bonding resins. The goal isto develop a tile that can act as a thermal storage devicethat will retain passively gained heat until later in theevening when the stored heat can be used to offset theheating requirements. Initial prototypes have beendeveloped. The next key step will be to attract amanufacturing partner.

Keywords: Thermal Storage, Phase Change, Tiles,Passive Heating

FENESTRATION MATERIALS DEVELOPMENT

6. DEVELOPMENT OF “ELECTROCHROMIC”MATERIALS AND COATINGSDOE Contact: Marc LaFrance (202) 586-9142

DOE has been working on a variety of electrochromicresearch projects to develop glazings that can control thevisual transmittance and solar heat gain for windows.Once commercialized, dynamic windows will significantlyreduce energy consumption and will reduce peak energydemand.

DOE $836,000, Sage cost-sharing $235,000SAGE Electrochromic Inc. Contact: Neil Sbar (507) 333-0078

Through competitively awarded contracts that includemanufacturer cost share, Sage is developing a “ceramic”based electrochromic device. Fundamental materialscience and deposition processes are being developed toallow for uniform, reliable, durable and cost effectivedevices that have a wide range of dynamic control.Currently, Sage is at the pilot production phase, althoughmaterial enhancements and yield improvements continueto be investigated. Samples have performed very wellthrough extended durability testing.

$500,000LBNL Contact: Steve Selkowitz (510) 486-5064

The recent discovery of metal hydride and non-hydrideswitchable mirrors that can be modulated from highlyreflecting (metallic) to highly absorbing (black) to highlytransparent (semiconducting) could be the basis for amuch simpler, less expensive device. Like tungstenoxide, the reflective metal hydrides can be used in eithera solid-state or gasochromic configuration. The hydrides


15

lend themselves particularly well to the gasochromicdevice which might require only the deposition of a thinmetal coating at high rate in a standard industrial sputtersystem (avoiding the need for thick, costly transparentconducting and electrolyte layers). Lithium-basedreflective electrochromic devices can use the sameelectrolytes and counter electrodes currently used forabsorbing devices. Like tungsten oxide, the active layer istransparent when reduced. Modulation of infraredtransmittance and reflectance is enhanced by theabsence of a transparent conductor.

Current tasks are to develop and further characterize theclass of variable reflectance electrochromic coatings.Explore alternative metals and replacement of hydrogen-based devices with lithium based electrochemistry.Issues that need to be addressed are morphologicalchanges during cycling, alloying for stability and improvedreflectivity, electrolyte interactions, and intralayerconductivity. Characterize spectral optical propertiesacross complete dynamic switching range. Continueinvestigation of degradation mechanisms in metal hydridesystems and develop mitigation strategies. Pursuedevelopment of prototype devices using both solid stateand gasochromic structures in collaboration withindustrial partners.

$150,000LANL Contact: Anthony Burrell (505) 667-9342

LANL has demonstrated that ionic liquids are effectivecomponents in electrochromic technologies. Chemicaland material analyses will be conducted to establish anionic liquid with dyes that are stable in the presence ofultraviolet light. Similar electrochromic devices have beencommercialized for rear view mirrors, but these are highlyunstable in the presence of UV which is needed for thewindow market. Initial prototypes have been developedwith a large dynamic range of solar heat control and havetested well at high and low temperatures. After UVstability has been established, the next key milestone willbe to conduct full scale durability tests, along with thedevelopment of polymer based fluid properties.

Keywords: Electrochromic, Dynamic Windows, SolarHeat Gain Coefficient, Solar Control, IonicFluids, Gasochromic

7. DEVELOPMENT OF TRANSPARENT AEROGELSR10/INCH FOR WINDOWSDOE $198,000, Aspen Aerogels cost-sharing$50,000DOE Contact: Marc LaFrance (202) 586-9142 Aspen Aerogels, Inc.: George Gould (508) 481-5058

Aspen Aerogels has developed non-transparent aerogelsfor a range of product applications that have beencommercialized. However, this competitively awardedresearch is focused on the development of highlytransparent sheet material that can be used in the spacegap of windows with a thermal resistance of R10 perinch. Technical challenges include the consistent andreliable production of highly transparent samples thatoffer improved structural integrity with high levels ofvisual clarity. Activities include development offundamental precursor chemical compositions, along withproduction development techniques to reducemanufacturing costs.

Keywords: Aerogels, Advanced Insulation

Distributed Energy & Electricity Reliability Program

16

DISTRIBUTED ENERGY & ELECTRICITY RELIABILITY PROGRAM

FY 2002

DISTRIBUTED ENERGY & ELECTRICITY RELIABILITY PROGRAM - GRAND TOTAL $32,000,000

HIGH TEMPERATURE SUPERCONDUCTIVITY FOR ELECTRIC SYSTEMS $32,000,000

DEVICE OR COMPONENT FABRICATION, BEHAVIOR OR TESTING $32,000,000

The 2nd Generation Wire Initiative 10,100,000Partnership with Industry 8,000,000Strategic Research 13,900,000


17

DISTRIBUTED ENERGY & ELECTRICITY RELIABILITY PROGRAM

HIGH TEMPERATURE SUPERCONDUCTIVITY FOR ELECTRIC SYSTEMS

High Temperature Superconductivity for Electric Systems works in partnership with industry to perform the research anddevelopment required for U.S. companies to commercialize High Temperature Superconductivity (HTS) for electric powerapplications. To achieve commercialization of the technology, the Superconductivity Program engages in research anddevelopment which aims to 1) improve the performance of superconducting wire while reducing manufacturing costs (WireTechnology), 2) demonstrate the applicability and the potential benefits of superconductivity in electric power systems(Systems Technology), and 3) conduct the fundamental investigations necessary to support the wire and systemsdevelopment (Strategic Research).

Wire research seeks methods to produce HTS wire that has higher current carrying capacity, better magnetic fieldcapabilities, reduced manufacturing costs, and better application characteristics such as durability, flexibility, and tensilestrength. Near-term research in this area focuses on conquering scale-up issues of mass-production wire technologies forcoated conductor YBCO (yttrium barium copper oxide). Longer-term wire research activities are investigating TBCCO(thallium barium calcium copper oxide) and other compounds for coated conductors, as well as the investigation ofunderlying superconductivity physics.

Systems research and development activities focus on the research, development, and testing of prototype HTS powersystem applications through industry-led projects. Research teams investigate adaptability issues for using superconductingwire in power system applications, which include transmission cables, generators, transformers, fault-current limiters, andflywheel electricity systems. In addition, program efforts target end-user applications in energy-intensive industries, includinglarge electric motors (over 5000 HP), MRI medical units, and magnetic separators. Application issues include thedevelopment of efficient cryogenic systems, cable winding techniques, and magnetic field research.

Strategic research conducts advanced, cost-shared, fundamental research activities to better understand relationshipsbetween the microstructure of HTS materials and their ability to carry large electric currents over long lengths. New projectswill be added to investigate the varied technical aspects of this key problem. The benefit will be higher performance wiresand inherently lower manufacturing costs. Also, work on enabling technologies such as joining HTS conductors to normalconductors will be supported as well as additional research on electrical losses due to alternating currents. These losses canbe reduced through better understanding of technical parameters. This research will support new discoveries andinnovations for the Second Generation Wire Development. These efforts complement research work funded by the DOEOffice of Science. This subprogram includes work on planning and analysis of potential program benefits as well ascommunication and outreach to gather information on future requirements for the HTS technologies and to maintain contactwith stakeholders.

FY 2002 saw a reorganization of the Superconductivity Program’s parent organization, the Office of Energy Efficiency andRenewable Energy (EERE). The High Temperature Superconductivity group became an element of the Distributed Energyand Electricity Reliability (DEER) Program. The DEER Program aims to improve the efficiency and reliability of the nation’selectricity transmission system.

FY 2002 also saw a decline in the annual operating budget of High Temperature Superconductivity for Electric Systems ofapproximately 16 percent from the prior year. This decline represented the first reduction in the program’s budget in the lasteight years. The result was somewhat lower spending on capital equipment for national laboratories, as well as thepostponement of the awarding of several new industry-led demonstration projects. Results that will be presented at the PeerReview in summer 2003 will determine what, if any, effect the reduction will have in achieving milestones for the long termcommercialization of the technology. The DOE contact is Jim Daley, 202-586-1165.


18

DEVICE OR COMPONENT FABRICATION, BEHAVIOROR TESTING

8. THE 2ND GENERATION WIRE INITIATIVE$10,100,000Argonne National Laboratory Contact:

U. Balachandran (630) 252-4250Brookhaven National Laboratory Contact:

David Welch (516) 282-3517Los Alamos National Laboratory Contact:

Dean Peterson (505) 665-3030National Renewable Energy Laboratory Contact:

Raghu Bhattacharya (303) 384-6477Oak Ridge National Laboratory Contact:

Robert Hawsey (615) 574-8057Sandia National Laboratory Contact: Paul Clem

(505) 845-7544 Industry Partners: American Superconductor

Contact: John Scudiere (508) 836-4200Intermagnetics General Corp. Contact:

Phillip Pellegrino (518) 346-1414Oxford Superconducting Technology Contact:

Seung Hong (732) 541-13003M Contact: Jonathan Storer (651) 733-6462MicroCoating Technologies Contact: Shara Shoup

(678) 287-2478

The Second Generation Wire Development capitalizes ontwo processing breakthroughs announced in 1995 and1996: the Ion-Beam Assisted Deposition (IBAD) processrefined by LANL and the Rolling Assisted BiaxialTexturing (RABiTS) technique pioneered by ORNL. Sincethen, industry-led consortia have evolved to developthese techniques into viable commercial processes formaking HTS wire.

Project subtasks are as follows:

Metallo-Organic Chemical Vapor Deposition (MOCVD) -Investigation continued on the development of a MOCVDtechnique for deposition of long-length, Yttrium-Barium-Copper Oxide (YBCO) conductors. The goal is toestablish processing conditions to deposit buffer andsuperconducting layers on textured metallic substrates.The substrates, buffer, and superconducting layers willbe characterized.

Thick HTS Films - Teams made significant progress in2002 in the development of thick HTS films. The films willbe deposited on flexible tapes containing oxide bufferlayers deposited by IBAD. Efforts continued to includeanalysis of electrical flow in thick films, and thedevelopment of new diagnostic techniques for identifying“bottlenecks” in the superconductors.

Substrate Development - Efforts at producing longlengths of textured nickel tape with all the appropriatecharacteristics for subsequent film growth (buffer layer(s)and superconductor) were continued.

IBAD Research - Program partners were completing thefirst phase of research on the IBAD approach. Electronbeam evaporation is 3M's selected method of depositionof all the layers. ORNL worked to characterize bare,textured nickel and films grown by a variety oftechniques, and to develop buffer layer andsuperconductor deposition technology. ORNL continuedpursuing a promising alternative to in-situ formation of theYBCO film, by electron beam co-evaporation of Y, Ba,and Cu. ORNL scientists worked on determining thethickness limits of epitaxial film formation, and assessingthe feasibility of rapid precursor depositions for the ex-situ precursor reaction process.

YBCO/RABiTS - Development and demonstration of thefabrication of lengths of YBCO/RABiTS using MOCVDtechnology continued. Mechanical and processingconditions needed to develop the desired surface textureand smoothness of the bare nickel were investigated. Inaddition to providing samples of short and long-lengthRABiTS, program researchers continued to characterizeproducts for uniformity of texture and electrical andmechanical properties.

Keywords: Superconductor, Coated Conductor, BufferLayers, Deposition, Textured Substrate

9. PARTNERSHIP WITH INDUSTRY$8,000,000

The Superconductivity Partnership with Industry (SPI) isan industry-led venture between the Department ofEnergy (DOE) and industrial consortia intended toaccelerate the use of high-temperature superconductivity(HTS) in energy applications. Each SPI team includes avertical integration of non-competing companies thatrepresent the entire spectrum of the research anddevelopment (R&D) cycle. That is, the teams include theultimate user of the technology (an electric powercompany), as well as a major manufacturing companyand a supplier of superconducting components. Eachteam also includes one or more national laboratories thatperform specific tasks defined by the team. The SPI goalis to design cost-effective HTS systems for electricitygeneration, delivery, and use. The funding amountincludes DOE’s share of the SPI design activities, as wellas parallel HTS technology development that directlysupports the SPI teams. All of these projects incorporatehigh-temperature superconducting wire into a utilityelectric application.


19

In FY 2002, several new projects were selected from asolicitation for industry-led, HTS power demonstrationprojects. However, due to lengthy negotiations and areduced HTS budget, several programs did not getawarded until late in 2002 or early 2003.


Current Controllers - LANL Researchers continued effortsto optimize the performance of a demonstration HTSCurrent Controller developed by General Atomics.Current controllers can be used on transmission anddistribution systems to protect system components fromdamaging power surges caused by ground faults.Compared to conventional devices, HTS currentcontrollers offer better protection and improved systemflexibility, reliability, and performance. Los AlamosNational Laboratory (LANL) scientists completed theoptimization of one of the devices three large coils, andwork is beginning on the other two.

LANL Contact: Dean Peterson (505) 665-3030

Motors - The project, led by Rockwell Automation,completed operational testing of a 1,000 horsepower (hp)motor in 2001. In 2002 design studies for a 5,000horsepower motor using HTS tape for the windings wereunderway. Rockwell’s success with the 1,000 horsepowermotor, which under load produced over 1,600horsepower, has the company looking forward to buildinga larger motor with new YBCO superconducting tapes.Superconducting motors can have a large impact onelectrical energy utilization through reduced losses andsize compared to conventional iron core motors. Thesereduced losses and the smaller size will be the drivingforce for the commercial introduction of superconductingmotors in industrial applications.

Rockwell Automation Contact: David Driscoll (216) 266-6002

Cold Dielectric Superconducting Transmission Cable -Southwire Company and DOE completed an agreementto enter a new phase of a partnership centered on thedevelopment of a power cable for real-world applications.Southwire began work, in conjunction with Oak RidgeNational Laboratory, on a new design for a 100-meter,three phase power cable to be installed at a substation inColumbus, Ohio. The project builds on an earlier SPIsuccess, the 30-meter, three-phase HTS cable that wascompleted in 2000 and feeds electricity to threeSouthwire manufacturing facilities.

Southwire Contact: David Lindsay (770) 832-4916

Warm Dielectric Superconducting Transmission Cable - Ateam led by Pirelli Cables and Systems and includingDetroit Edison, American Superconductor, and LosAlamos National Lab continued efforts to operate aprototype HTS cable in a utility substation in Detroit. Theproject has had to overcome problems with vacuum leaksin the cable, and Pirelli hopes to commission one phaseof the cable in the next few months. The HTS cable willlead to smaller, more efficient electricity transmissionlines in utility networks.

Pirelli Contact: Nathan Kelley (803) 356-7762

Flywheel Electricity System - FY 2002 saw the successfuldemonstration of a 10 kWh Flywheel Electricity Systemdesigned and built by a team led by Boeing. HighTemperature Superconducting bearings, made from abulk superconductor material, are an enabling technologyfor the flywheel design. The bearings allow the flywheelto store electricity with increased efficiency. A follow-onproject was awarded late in 2002 for the demonstration ofa 35 kWh power risk management system using theflywheel and superconducting bearings.

Boeing Contact: Mike Strasik (425) 237-7176

Reciprocating Magnetic Separator - This project teamsDuPont with the National High-Magnetic Field Laboratoryto develop a reciprocating magnetic separator. Thesedevices are used in the materials field and aretraditionally large consumers of utility electricity. In 2001,a ¼ scale demonstration unit was assembled and tested.The unit exceeded expectations, and in 2002 DuPontreached an agreement with DOE to build and test a full-scale, pre-production Reciprocating Magnetic Separator.

DuPont Contact: Chris Rey (302) 695-9470

Transformer - Waukesha Electric Systems (WES) isleading a team that includes ORNL, IGC-SuperPower,and Rochester Gas and Electric to build and operate a5/10 MVA alpha prototype cryocooled HTS powertransformer on the Wisconsin Electric Power utility grid.The prototype will power WES’ main transformermanufacturing plant. In 2002, the team completed theassembly of the transformer and began testing of theunit. Some high-voltage problems have surfaced, andWaukesha and ORNL are working to overcome theseobstacles.

ORNL Contact: Bob Hawsey (865) 574-8057

MRI - Oxford Superconducting Technology began aproject in 2002 to demonstrate a cost-effective, open-geometry MRI (magnetic resonance imaging) system.MRIs represent the greatest existing market for lowtemperature superconductors, and use tremendousamounts of electricity to create their powerful magnetic


20

fields. HTS technology has the potential to allow forsmaller, more flexible MRI designs, as well as hugereductions in the amount of electricity and utilityinfrastructures required to operate the devices. Oxfordhas completed several proof-of-concept devices, but thenew project will involve establishing a continuous meltprocess for dip-coated BSCCO 2212 superconductingtape.

Oxford Contact: Kenneth Marken (732) 541-1300

Generator - General Electric Corporate Research andDevelopment is leading a team that includes ORNL,American Electric Power, and PG&E to develop anddemonstrate a 100 MVA HTS generator. HTS generatorswill have improved efficiency, higher capacity, andimproved reactive power capabilities. The project wasawarded in 2002, and GE began conceptual designs andcomponent acquisition/fabrication.

ORNL Contact: Bob Hawsey (865) 574-8057

Keywords: Motor, Generator, Magnetic Resonance,Current Controller, Transmission Cable,Flywheel, Separator

10. STRATEGIC RESEARCH$13,900,000Argonne National Laboratory Contact:

U. Balachandran (630) 252-4250Brookhaven National Laboratory Contact:

David Welch (516) 282-3517Los Alamos National Laboratory Contact:

Dean Peterson (505) 665-3030National Renewable Energy Laboratory Contact:

Raghu Bhattacharya (303) 384-6477Oak Ridge National Laboratory Contact:

Robert Hawsey (615) 574-8057Oxford Superconducting Technology Contact:

Seung Hong (732) 541-1300University of Wisconsin Contact:

David C. Larbalestier (608) 263-2194

Strategic research and development projects in theprogram are crucial for the discovery of newtechnologies, such as RABiTS and magneto-opticalimaging (MOI), that make the program a world leader inthe race to bring HTS electric power technologies tomarket. Critical theoretical calculations, new materialevaluation, and process development support theprogram’s industry-directed Cooperative Research andDevelopment Agreement (CRADA) work and the SPIapplication projects and provide a foundation for futurecollaborations and progress toward HTScommercialization by industry.

Work by all organizations in strategic research comprisesa diverse set of topics from characterization techniques to

wire processing to applications development. As theseactivities mature, they evolve into more cohesive effortsdevoted to improving mechanical and electrical propertiesof wire and new devices.


Strategic projects continued to focus on the developmentof improved substrates for both IBAD and RABiTSprocesses, and deposition processes for buffer layersand the superconductor layer. Characterization of bufferand superconductor layers attempted to correlateprocessing parameters with final wire performance.Projects were active at all six national laboratories.

Wire Characterization - Program participants werecontinuing the characterization of microstructural andsuperconducting properties of second-generation wire toimprove understanding of Jc-limiting factors related to theformation and growth kinetics of high-temperaturesuperconductors. On-line characterization instrumentsare being developed to maintain quality control in thefabrication of long lengths of HTS wire. The engineeringscale-up will require the integration of characterizationand the process control of the fabrication parameters.

Oxide Buffer Layer Research - Work on developing sol-gel derived oxide buffer layer systems continued in 2002.A variety of deposition and processing strategies werebeing investigated to develop a fundamentalunderstanding of this deposition approach and tooptimize film properties. Additionally, Sandia scientistsworked on developing high-quality, solution-derived, 123-type superconducting films for coated conductorapplications.

Coated Conductor Processing - Research anddevelopment of YBCO coated conductor processingcontinued in a variety of subtasks. Scale-up issues arebeing defined and addressed. Developing the capabilityto fabricate long lengths on RABiTS, using electron beamevaporation and an existing ultra-high vacuum, reel-to-reel system remained a priority. Lengths of RABiTS werebeing provided for internal use as well as for variouspartners.

PLD Deposition - A system and process for deposition ofYBCO by Pulse Laser Deposition on moving substrateswas being developed by the utilization of a radiantheating system, along with sample translation. Also,improved texture in substrates with reduced magnetismwas under development. New RABiTS architectures, withconductive and simpler structures, were investigated.

Process Technology - DOE partners worked towarddeveloping and demonstrating process technologyneeded for epitaxial growth of buffer layers bymetalorganic decomposition. A specific objective of the


21

project is to develop alkoxide precursor methods fordeposition of buffer layers compatible with texturedmetallic substrates appropriate to long-length conductormanufacture and compatible with AmericanSuperconductor’s YBCO deposition methods.

The program supports a broad range of activities whichconcentrate on the underlying principles of HTS anddeveloping an understanding of how these principlesaffect final HTS material properties. Collaborators in theactivities have worked on understanding reaction kinetics,effects of stoichiometry on the superconductingproperties, introducing flux pinning centers, andmonitoring current transport in HTS conductors.

ORNL funded two university research and developmentprojects in FY 2002. Researchers at Stanford Universityinvestigated ion-beam assisted deposition of buffer layersand in-situ deposition of YBCO by electron beamevaporation. The University of Wisconsin conductedresearch on BSCCO critical currents and microstructures,YBCO coated conductor microstructure, and pulse tubecryocooler technology.

AC Loss Characterization - Attempts to characterize AClosses in HTS tapes, under conditions which simulate theelectromagnetic conditions in utility devices, continued.Program participants worked to design a cable configuredto minimize AC losses.

Keywords: Superconducting Tapes, Flux Pinning,Thallium Conductor, Bismuth Conductor


22

FREEDOMCAR & VEHICLE TECHNOLOGIES

FY 2002

FREEDOMCAR & VEHICLE TECHNOLOGIES - GRAND TOTAL $39,009,000

MATERIALS TECHNOLOGIES PROGRAM $39,009,000

AUTOMOTIVE PROPULSION MATERIALS $2,845,000

Technical Project Management 300,000Low-Cost, High Energy Product Permanent Magnets 250,000Characterization of Permanent Magnets 50,000Carbon Foam Thermal Management Materials for Electronic Packaging 200,000Mechanical Reliability of Electronic Ceramics and Electronic Ceramic Devices 150,000Microwave-regenerated Diesel Engine Exhaust Particulate Filter Technology 450,000Rapid Surface Modifications of Aluminum Engine Block Bores for Weight Reduction 200,000Material Support for Nonthermal Plasma Diesel Engine Exhaust Emission Control 200,000Low-Friction Coatings for Fuel Cell Air Compressors 200,000Microstructural Characterization of PEM Fuel Cells 200,000Inorganic Polymer Electrolyte Membrane Electrode/support Development 75,000Carbon Foam for Radiators for Fuel Cells 125,000Fabrication of Small Injector Orifices 180,000Technology for Producing Small Holes in Advanced Materials 115,000Electrochemical NOx Sensor for Monitoring Diesel Emissions 150,000

AUTOMOTIVE LIGHTWEIGHT VEHICLE MATERIALS $15,750,000

Low-Cost High Performance Wrought Aluminum Components for Automotive Applications 450,000Low-Cost High Performance Cast Light Metals for Automotive Applications 500,000Advanced Materials and Processes for Automotive Applications 550,000Technology Assessment and Evaluation 1,650,000Advanced Joining Technologies 1,500,000High Strain Rate Deformation of Materials 925,000Reinforced Composite Materials, Durability, and Enabling Technologies 750,000USAMP Cooperative Agreement 6,300,000Development of Low-Cost Carbon Fiber 1,900,000Recycling 350,000Structural Reliability of Lightweight Glazing Alternatives 350,000High Rate Processing Technologies for Polymer Composite Materials 525,000

HEAVY VEHICLE PROPULSION MATERIALS $4,944,000

Smart Materials for Fuel System Actuators 400,000Cost-Effective Smart Materials for Diesel Engine Applications 300,000Manufacturing Technology for Cermet Components 75,000Intermetallic-Bonded Cermets 100,000High-Toughness Materials 300,000Materials for Exhaust Aftertreatment 400,000Catalyst Characterization 200,000Diesel Engine Particulate Filter 300,000Development of NOx Sensors for Heavy Vehicle Applications 200,000Field Emission Analytical Microscopy for Characterization of Catalyst Microstructures and

Deactivation Mechanisms 200,000Advanced Materials for Lightweight Valve Train Components 189,000Thick Thermal Barrier Coatings (TTBCs) for Low Emission, High Efficiency Diesel Engine

Components 200,000


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FREEDOMCAR & VEHICLE TECHNOLOGIES (continued)

FY 2002

HEAVY VEHICLE PROPULSION MATERIALS (continued)

Mechanical Characterization 85,000NDE of Diesel Engine Components 200,000Durability of Diesel Engine Component Materials 200,000Life Prediction of Diesel Engine Components 200,000Low-Cost Manufacturing of Precision Diesel Engine Components 235,000Cylindrical Wire EDM and Temperature Measurement 75,000Development of Low-Cost Austenitic Stainless Diesel Engine Components with Enhanced

High-Temperature Reliability 160,000TiAl Nanolaminate Composites 100,000Synthesis of Powders for Titanium Carbide/Nickel Aluminide Cermets 75,000Diesel Exhaust Gas Recirculation Corrosion Effects 50,000Durability of Diesel Engine Component Materials 200,000Rolling Contact Fatigue 200,000IEA Implementing Agreement for a Programme of Research and Development on Advanced

Materials for Transportation Applications 200,000Testing Standards 100,000

HIGH STRENGTH WEIGHT REDUCTION MATERIALS $9,870,000

Design, Analysis and Development of Lightweight Frames for Truck and Bus Applications 1,275,000Development of Advanced Casting Technologies for Production of High Integrity Truck

Components 800,000Advanced Forming Technologies for Lightweight Alloys 675,000Development of Carbon Monoliths for Safe, Low Pressure Adsorption Storage and Release

Natural Gas 600,000Improved Materials for Heavy Vehicle Brake and Friction Applications 675,000High Conductivity Carbon Foams for Thermal Management 125,000Advanced Joining Technology Development 500,000Development of Advanced Materials for Heavy Vehicle Applications 1,250,000Implementation of Lightweight Materials in Heavy Vehicle Structural Applications 2,470,000Technology Assessment and Evaluation 1,500,000

HIGH TEMPERATURE MATERIALS LABORATORY $5,600,000

The High Temperature Materials Laboratory User Program 5,600,000


24

FREEDOMCAR & VEHICLE TECHNOLOGIES

The Office of FreedomCAR and Vehicle Technologies (OFCVT) seeks to develop, in cooperation with industry, advancedtechnologies that will enable the U.S. transportation sector to be energy efficient, shift to alternative fuels and electricity, andminimize the environmental impacts of transportation energy use. Timely availability of new materials and materialsmanufacturing technologies is critical for the development and engineering of these advanced transportation technologies.Materials Technologies R&D is conducted by the Materials Team to address critical needs of automobiles and heavyvehicles. These activities are closely coordinated with other Department programs and those of other Federal and non-governmental organizations to ensure non-duplication of efforts. Another important aspect of these activities is thepartnership between the Federal government laboratories and U.S. industry, which ensures that the R&D is relevant and thatfederal research dollars are highly leveraged. Much of the research that is focused on automobiles is conducted incooperation with the auto industry through the United States Consortium for Automotive Research (USCAR) through theFreedomCAR partnership. Likewise, the 21st Century Truck Partnership is the umbrella organization which coordinates muchof the heavy vehicle materials research with the trucking industry.

Within the FreedomCAR program, the bulk of the materials R&D is carried out through the Materials Technologies program,with additional specialty materials R&D in the Electric Drive Technologies program. The Materials Technologies programaddresses: a) Automotive Propulsion Materials to develop material solutions for electric drive systems and engine andemission control systems, and b) Automotive Lightweight Vehicle Materials to reduce vehicle weight and thereby reduce fuelconsumption. The program seeks to develop advanced composites and metals with the required properties and theprocesses needed to produce them at the costs and volumes needed by the automotive industries. Improved materials forbody, chassis, and powertrain are critical to attaining the challenging performance standards for advanced automotivevehicles. The DOE contacts are Rogelio Sullivan (202) 586-8042, for automotive propulsion materials and JosephCarpenter, 202-586-1022, for automotive lightweight vehicle materials.

Within the Materials Technologies program, the truck, bus, and heavy vehicle materials research are addressed through a)Heavy Vehicle Propulsion System Materials, and b) High Strength Weight Reduction Materials. In collaboration with U.S.industry and universities, efforts in heavy vehicle propulsion system materials focus on the materials technology critical tothe development of the low emission, 55 percent efficient (LE-55) heavy-duty and multi-purpose Diesel engines, such as:manufacturing of ceramic and metal components for high-efficiency turbochargers and superchargers; thermal insulation, forreducing engine block cooling, lowering ring-liner friction and reducing wear; high-pressure fuel injection materials; andexhaust after treatment catalysts and particulate traps. In the area of high strength weight reduction materials, energysavings from commercial trucking is possible through application of high strength materials which can reduce the vehicleweight within the existing envelope so as to increase payload capacity, and thereby reducing the number of trucks neededon the highways. Increased safety can be obtained by new brake materials and by incorporating highly shock absorbentmaterials in truck structures for improved control and crashworthiness. The DOE contact is Sid Diamond (202) 586-8032.

The High Temperature Materials Laboratory (HTML) at the Oak Ridge National Laboratory is a modern research facility thathouses in its six user centers, a unique collection of instruments for characterizing materials. It supports a wide variety ofhigh-temperature ceramics and metals R & D. The HTML enables scientists and engineers to solve materials problems thatlimit the efficiency and reliability of advanced energy-conversion systems by providing access to sophisticated state-of-the-art equipment (which few individual companies and institutions can afford to purchase and maintain) and highly trainedtechnical staff. The DOE contact is James Eberhardt (202) 586-9837.

MATERIALS TECHNOLOGIES PROGRAM

AUTOMOTIVE PROPULSION MATERIALS

11. TECHNICAL PROJECT MANAGEMENT$300,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556

The Automotive Propulsion Materials Program focuseson enabling materials technologies that are critical inremoving barriers to the power electronics, fuel cell, andcompression-ignition, direct-injection (CIDI) enginecombustion and emissions control research programs.

The objective of this effort is to assess the materialstechnology needs in each of these areas for hybridelectric or fuel cell vehicles, formulate technical plans tomeet these needs and prioritize and implement a long-range research and development program.

Keywords: Advanced Heat Engines, Alloys, AutomotiveApplications, Carbon, Coordination, Metals,Management, Structural Ceramics


25

12. LOW-COST, HIGH ENERGY PRODUCTPERMANENT MAGNETS$250,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ANL Contact: Y. S. Cha (630) 252-5899

The objective of this work is to develop a low-costprocess for the fabrication of high strength NdFeBpermanent magnets to enable significant size and weightreductions of traction motors for hybrid electric vehicles.A facility was established at Argonne National Laboratoryfor pressing permanent magnets in the high fields (9 T) ofa superconducting solenoid. The solenoid better alignsthe magnetic domains of NdFeB powder during pressinginto green compacts. The energy product (MGOe) andremnant field Br(kG) of magnets produced in this facilityshowed a strong dependence on the magnitude of thealignment field H(T). Achieved energy productimprovements of 15% for thin near-final-shape magnets,production of which is the current cost-saving thrust in thePM industry. Additional PMs made with relatively smalllength-to-diameter ratio (L/D<0.5) supports the previousfindings. Carried out electromagnetic code study of grainalignment in powder compacts. The results show that thedistortion of the alignment field (caused by the self-field ofthe compact) is proportional to the density of the compactand inversely proportional to the magnitude of thealignment field. These results will help to provide scale updesign rules to industry. Collaborated with Oak RidgeNational Laboratory and Ames Laboratory oncharacterizing the microscopic texture (alignment) of PMsmade at Argonne and on processing the NdFeB powderfor bonded PMs at the 9-Tesla superconducting magnetat ANL; respectively.

Keywords: NdFeB, Permanent Magnets,Superconducting Solenoids, TractionMotors

13. CHARACTERIZATION OF PERMANENTMAGNETS$50,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: E. A. Payzant

(865) 574-4472

The purpose of this work is to quantify the relationshipbetween processing parameters and the crystalchemistry and microstructure of NdFeB permanentmagnets fabricated at Argonne National Laboratory andby commercial suppliers. The microscopic texture(alignment) of permanent magnets made in the Argonne

axial-die press facility was characterized and correlatedthe alignment with macroscopic magnetic properties.

Keywords: NdFeB, Permanent Magnets

14. CARBON FOAM THERMAL MANAGEMENTMATERIALS FOR ELECTRONIC PACKAGING$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: Nidia Gallego

(865) 574-5220

The objective of this work is to collaborate withautomotive partners to develop carbon foam heatexchanger and heat sink designs for high-powerelectronics that dissipate 30 W/cm2 at temperatures ofless than 60°C with lower cooling flow rates than currentdesigns. Research with the National Security Agency hasshown that the carbon foams can be used as anevaporative substrate in a totally passive heat pipe andallow up to 115 W/cm2 power density in the electronicsand still maintain the required low temperatures ofoperation of 56/C. In addition, improvements in thefabrication process resulted in foams with a more uniformdensity distribution, higher compressive strengths (up to100% higher) and, hence, increased durability andmachinability.

Keywords: Carbon Foam, Heat Sinks, Heat Transfer,Power Electronics, Thermal Management

15. MECHANICAL RELIABILITY OF ELECTRONICCERAMICS AND ELECTRONIC CERAMICDEVICES$150,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: A. A. Wereszczak

(865) 576-1169

The objectives of this task are to assess and predict themechanical reliability of electronic devices with emphasison those used for automotive power electronics (e.g.,capacitors) and to correlate the mechanicalcharacterization of polymer film capacitors developed bySandia National Laboratories (SNL) to the dielectricbehavior.

Received three series of polymer film samples from SNLand characterized them using a mechanical propertiesmicroprobe. Performed indentation studies with amechanical properties microprobe to characterizehardness and Young’s modulus on a suite of SNLdielectric films. Purchased a universal test frame withfilm-gripping capabilities and that can perform tensile test


26

at high temperatures, and verified its operation andaccuracy.

Keywords: Electronics, Failure Analysis, LifePrediction, Mechanical Properties,Multilayer Capacitors

16. MICROWAVE-REGENERATED DIESEL ENGINEEXHAUST PARTICULATE FILTER TECHNOLOGY$450,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556Industrial Ceramic Solutions Contact: R. Nixdorf

(865) 482-7552

The objective of this work is to develop a DieselParticulate Filter that demonstrates greater than 95percent capture efficiency and can be regenerated towithin 95 percent of the new filter condition with the useof microwave energy. During the year a microwaveregeneration system was designed and built that iscapable of performing on a PNGV-type diesel engine.The microwave filter system demonstrated 95 percentefficiency on a 1.9-L Volkswagen engine in a test cell atOak Ridge National Laboratory and 95% filterregeneration frequency on a Volkswagen Jetta vehicle.An improved pleated-filter cartridge microwave filtersystem was designed and bench tested for installationand track testing on a Ford F-250 7.3-L diesel pickup.The microwave filter system fuel penalty, as calculatedfrom these test results, was an impressively low 0.3percent and the engine exhaust backpressure wasreduced significantly with the pleated filter cartridge.

Keywords: Carbon Particulates, Diesel, Filters,Microwave Regeneration

17. RAPID SURFACE MODIFICATIONS OFALUMINUM ENGINE BLOCK BORES FORWEIGHT REDUCTION$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: C. Blue

(865) 574-5112

Innovative, rapid, high-density surface modificationprocesses are being used to develop a new, durability-enhancing coating for automotive applications such asaluminum engine block cylinder bores, compressorhousings, fuel pumps and sealing surfaces. The concernabout one such coating (Fe-Cr-B-Mn-Si) was associatedwith the porosity and hardness of the coating and thebonding characteristics of the coating to the substrate.Experiments were conducted by varying the arc lamp’sreflector geometry, amperage (i.e., power density), andpulse or exposure time. It was shown that there was asignificant reduction in porosity, increased coating

hardness, and adequate metallurgical bonding. Thisresearch demonstrates the plasma arc lamp’s capabilityto rapidly fuse coatings in an air environment. Aprocedure was also developed using the tungstenhalogen lamp to dramatically reduce the time required tocure an epoxy used to join automotive body panels. Theprocess was so successful, that is was implemented on aproduction line for the Ford Lincoln LS vehicle.

Keywords: Aluminum, Cost Reduction, Engines, HardCoatings, Wear

18. MATERIAL SUPPORT FOR NONTHERMALPLASMA DIESEL ENGINE EXHAUST EMISSIONCONTROL$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: S. D. Nunn

(865) 576-1668

The objective of this work is to identify appropriateceramic materials, develop processing methods, andfabricate complex-shaped ceramic components that willbe used in Pacific Northwest National Laboratory(PNNL)-designed nonthermal plasma (NTP) reactors forthe treatment of diesel exhaust gases. Ceramic dielectriccomponents that were produced using the newfabrication process which utilizes commercially availabletape cast ceramic materials were tested at PNNL. Threeof the ceramic components were stacked in a test fixtureand connected to a voltage supply to generate a plasmadischarge. The tests demonstrated that the componentsproduce a uniform plasma with no dielectric breakdownunder operating conditions. In a companion effort, asealing glass was identified for joining together theceramic components of the NTP reactor assembly. Thesealing glass will be used to bond together the stack ofdielectric plates and to seal the assembly to prevent theescape of exhaust gases.

Keywords: Aftertreatment, Ceramics, Diesel,Gelcasting, Nonthermal Plasma

19. LOW-FRICTION COATINGS FOR FUEL CELL AIRCOMPRESSORS$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ANL Contact: G. R. Fenske (630) 252-5190

The objective of this work is to develop and evaluate thefriction and wear performance of low-friction materialsand coatings for fuel cell air compressor/expandersystems. The impact of Argonne’s near frictionlesscarbon (NFC) coating on the performance of a noveljournal air bearing (developed by Meruit) was evaluatedin a series of bearing tests. The NFC coating enabled the


27

development of the low-cost bearing technology and wassuccessfully demonstrated in a test that experienced over10,000 start-stop cycles (without the coating, the bearingseized during the first cycle). Argonne also workedclosely with Mechanology, LLC to evaluate the frictionand wear properties of materials for a novel aircompressor they were developing for DOE. The study,which is still in progress, has identified the importance ofthermal conductivity as a key property in determining thetribological performance of polymers at elevated speeds.

Keywords: Air Compressors, Carbon, Friction, NearFrictionless Coating, Scuffing, Wear

20. MICROSTRUCTURAL CHARACTERIZATION OFPEM FUEL CELLS$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: D. Blom

(865) 241-3898

The objectives of this effort are to optimize the catalystmicrostructure and distribution in membrane electrodeassemblies (MEAs) for low cost and high performanceand to understand the effects of microstructure andmicrochemical composition on the performance andaging characteristics of the fuel cell. A new cryo-ultramicrotomy facility was inaugurated at the HighTemperature Materials Laboratory at Oak Ridge NationalLaboratory. Cryo-ultramicrotomy is believed to be a keypreparation step for thinner MEA cross-sections that willallow higher-resolution and more definitivecharacterization. An MEA aged to failure at 1200 hours ofoperation (using a very aggressive aging schedule) wascharacterized for its chemical homogeneity and catalystparticle size. Unlike previous aged MEAs, no evidence ofa chemically distinct layer at the membrane/electrodeinterface was seen. We believe the aging protocol usedwas so aggressive that massive bulk membrane failureoccurred before the chemical aging of the membraneinterface. Both the cathode and anode catalyst particlescoarsened during the aging process, though the particlesin the anode grew a statistically significant amount morethan the cathode catalyst particles. Careful developmentof relevant accelerated aging protocols is clearlynecessary to provide data applicable to actual in-userconditions.

Keywords: Catalysts, Fuel Cells, Platinum MembraneElectrode Assemblies, TEMCharacterization

21. INORGANIC POLYMER ELECTROLYTEMEMBRANE ELECTRODE/SUPPORTDEVELOPMENT$75,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: M. A. Janney

(865) 574-4281

The goal of this effort is to develop electrically conductingelectrodes/supports and catalytically active ceramicsandwich layers for use in inorganic microporous PEMmembranes based on nanoparticles of TiO2 and Al2O3.The materials developed in this project will be used assubstrates at the University of Wisconsin for thefabrication of microporous inorganic proton exchangemembranes. A process was developed to fabricateelectrically conducting, porous nickel materials that willbe initially used as substrates. An improved graphitefiber-based substrate/electrode having the requisitechemical compatibility with the PEM environment is beingdeveloped to replace the porous nickel. After successfuldevelopment of the substrates, a second process wasdevised to deposit microporous titania with carefullycontrolled particle size and permeability onto thesubstrate. Sandwich layers of microporous titania onporous nickel were fabricated and shipped to theUniversity of Wisconsin. The nickel/titania sandwichmaterial was found to be an appropriate surface uponwhich to deposit the nanoparticle membrane.

Keywords: Ceramics, Fuel Cells, Membranes, TitaniumOxide

22. CARBON FOAM FOR RADIATORS FOR FUELCELLS$125,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: A. D. McMillan

(865) 241-4554

The purpose of this work is to develop compact,lightweight, and more efficient radiators for fuel-cell-powered vehicles utilizing Oak Ridge NationalLaboratory’s unique, high-conductivity carbon foam.Research focused on durability and environmentalcharacterization in this year. Results have shown thatvibration has no apparent effect on the foams materialproperties or the soldered interface. However, it wasshown that a significant decrease in thermal properties(up to 50%) can be found under corrosion with radiatorfluid and certain solders and base plates. It was foundthat the corrosion is attacking the substrate and not thefoam, and therefore, methods to protect the substrate willprove useful in decreasing corrosion problems. Last,corrugated heat exchangers were found to reduce the


28

pressure drop by more than an order of magnitude, whileaffecting the heat transfer minimally.

Keywords: Carbon Foam, Heat Exchangers, HeatTransfer, Radiators

23. FABRICATION OF SMALL INJECTOR ORIFICES$180,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ANL Contact: G. R. Fenske (630) 252-5190

Decreasing the size of fuel injector orifice holes enhancesatomization of fuel in CIDI engines and thus presents apotential approach to achieve more stringent particulateemission standards. Currently, electrodischargemachining can routinely by used to fabricate orifices assmall as 125 mm in diameter. Ideally, however, the orificediameter should be reduced to 50 mm or less. The goalof this research is to develop an alternative approach tofabricating small fuel injector orifice nozzles by coatingthe inner surfaces of current mass-produced injectororifices – in other words, we will start with fuel injectornozzles/orifices that are currently produced in massquantities, and develop coating processes to coat theinside surface to reduce the orifice to the size required.Aqueous-based and vacuum-based processes are beingconsidered, with an initial focus on electroless coatingprocesses. During the first year of this project, anelectroless plating process was selected and developedto coat the inner surfaces of commercial fuel injectors.The process was demonstrated on commercial injectorsas being able to reduce the orifices from 0.2 mm to 0.1mm. Work is in progress to achieve a 0.05 mm diameterorifice.

Keywords: Fuel Injectors, Nozzles, Orifice, Coating

24. TECHNOLOGY FOR PRODUCING SMALL HOLESIN ADVANCED MATERIALS$115,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: S. D. Nunn

(865) 576-1668

The objective of this project is to explore new methods forforming ultra-small (<50mm) holes in advanced materialsthat may be used for fuel injector nozzles in dieselengines. Carbide-based cermets (ceramic/metalliccomposites) and high-temperature structural ceramicsare candidate materials to be used in this study. Tworelated approaches were developed for producing holesin gelcast alumina ceramic. The basic approach forforming the holes was to incorporate either organic fibersor metal wires within the molded gelcast ceramic green(unsintered) body. The organic fibers burn away duringthe high-temperature sintering process that is used to

densify the ceramic and leave fine holes in the densematerial. The metal wires can be removed from the greenceramic prior to sintering, leaving holes that remain afterdensification. Using these methods, holes that wereabout 30µm in diameter and as long as 20mm wereproduced.

Keywords: Ceramics, Cermets, Diesel, Fuel Injectors,Gelcasting

25. ELECTROCHEMICAL NOX SENSOR FORMONITORING DIESEL EMISSIONS$150,000DOE Contact: N. L. Garland (202) 586-5673LLNL Contact: R. S. Glass (925) 423-7140LLNL Principal Investigator: L. P. Martin

(925) 423-9831

The purpose of the proposed research is to developtechnology for low cost, high sensitivity, on-boardsensors for the detection of NOx in diesel exhaust. Thesensors will be based upon metal oxide/solid electrolytetechnology which has demonstrated significant potentialfor the detection of hydrocarbon emissions in automobileexhaust. Sensor material and design will be optimized foran environment comparable to the exhaust stream of theCIDI engine. An oxide electrode material providingsuperior response has been identified for anamperometric NO sensor. The sensor operates at 650oC,and has excellent NO sensitivity and a fast response timeof less than 1 second. The high signal-to-noise ratioindicates a short-term sensitivity limit £ 25 ppm NO.Current efforts are focused on the long-term stabilizationof the electrode microstructure, which tends to coarsenduring amperometric operation. Coarsening of theelectrode microstructure can lead to drifting of the sensorbaseline. Future efforts will be directed towards continuedrefinement of the electrode material/microstructure,investigation of the cross sensitivity to other gasses, andsensor integration.

Keywords: NOx, Electrochemical Sensor, CIDI, DieselExhaust

AUTOMOTIVE LIGHTWEIGHT VEHICLE MATERIALS

26. LOW-COST HIGH PERFORMANCE WROUGHTALUMINUM COMPONENTS FOR AUTOMOTIVEAPPLICATIONS $450,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069PNNL Contact: Mark Smith (509) 376-2847Laboratory Partners: LANL, PNNLIndustry Partners: Alcoa

The objectives of this effort are: to developelectromagnetic forming (EMF) technology that will


29

enable the economic manufacture of automotivecomponents from aluminum sheet; and to evaluatestructural extrusion formability, to experimentally validatestress-based forming limits, and to validate enhancedformability through the application of non-proportionalloading.

Keywords: Aluminum, Sheet Forming, Extrusion,Hydroforming, Electromagnetic Forming

27. LOW-COST HIGH PERFORMANCE CAST LIGHTMETALS FOR AUTOMOTIVE APPLICATIONS$500,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: LLNL, ORNL, SNL, INEEL,

ANLIndustry Partners: USAMP (Ford, GM, Chrysler)

The objectives of this project are to develop the tools thatwill be used to enhance the application of castmagnesium components. These tools include: numericalsimulation modeling to predict mold cavity fill and castingsolidification for die cast components, simulation modelsthat predict the cast component monotonic and cyclicproperties, and development of non-destructiveevaluation equipment, procedures, and process sensors.

Keywords: Magnesium, Cast Metals, Automotive, DieCasting, Simulation Modeling

28. ADVANCED MATERIALS AND PROCESSES FORAUTOMOTIVE APPLICATIONS$550,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069PNNL Contact: Mark Smith (509) 376-2847Laboratory Partners: PNNLIndustry Partners: USAMP (Ford, GM, Chrysler),

MC-21

The objective of this effort is to develop a new low-costprocess for the efficient on-site stir-casting of aluminummetal matrix composites suitable for the production ofautomotive components such as brake rotors.

Keywords: Metal Matrix Composites, Aluminum,Casting, Brake Rotors

29. TECHNOLOGY ASSESSMENT AND EVALUATION$1,650,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contacts: Phil Sklad (865) 574-5069 and

Dave Warren (865) 574-9693Laboratory Partners: ANL, ORNL, PNNL

The objective of this effort is: to provide assessment ofthe cost effectiveness of various technologies; toevaluate the ability of the industrial infrastructure toaccommodate emerging technologies; to verify, throughmodeling and analysis, that technologies developed willyield weight reductions commensurate with programgoals; to provide guidance to program management as toappropriate investments for R&D funding; and to fundinnovative research with small business.

Keywords: Cost, Infrastructure, TechnicalManagement, Assessment

30. ADVANCED JOINING TECHNOLOGIES$1,500,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contacts: Phil Sklad (865) 574-5069 and

Dave Warren (865) 574-9693Laboratory Partners: LBNL, ORNL, PNNL

The objective of this effort is: to develop non-destructiveevaluation and testing techniques that are sufficientlyfast, robust in the manufacturing environment, accurateand cost-effective to be suitable or on-line inspection ofspot-welded automotive structures; to develop joiningtechnologies and evaluate joint performance for dissimilaraluminum and aluminum-steel materials in automotiveapplications; to develop coupled thermo-electric,mechanical-metallurgical models of electrode deformationduring resistance spot welding of galvanized steel andaluminum; to develop new experimental methods andanalysis techniques to enable hybrid joining as a viableattachment technology in automotive structures byevaluating composite/metal joints, time-dependentdamage mechanisms, and environmental exposure forthe ultimate development of practical modelingtechniques that offer global predictions for joint durability;and to develop innovative attachment techniques forjoining materials subjected to crash scenarios and todevelop materials and joint test methods for joints andpredictability tools.

Keywords: Joining, Dissimilar Materials, NDE,Aluminum, Galvanized Steel, PolymerComposites


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31. HIGH STRAIN RATE DEFORMATION OFMATERIALS$925,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNLIndustry Partners: AISI

The objective of this effort is: to develop numericalmethods and guidelines in order to realistically assessthe influence that the properties of strain rate dependentmaterials exert in crashworthiness computations; todevelop the capability of testing new lightweight materialsat strain rates comparable to those observed inautomobile crashes; to define the behavior of compositeand metallic materials in the transition range from nearstatic to highly dynamic failures; to developexperimental/analytical matrix for validation testing theevaluate constitutive models, work hardening effects,strain-rate sensitivity effects of selected high strengthsteels; and to develop materials and joint test methodsfor joints and predictability tools.

Keywords: Strain Rate, Crashworthiness, NumericalModeling

32. REINFORCED COMPOSITE MATERIALS,DURABILITY, AND ENABLING TECHNOLOGIES$750,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Dave Warren (865) 574-9693Laboratory Partners: ORNLUniversity Partners: University of Tennessee,

University of Tulsa, University of Michigan,University of California-Santa Barbara, WayneState University, Stanford University, Universityof Nottingham.

Industry Partners: USAMP/Automotive CompositesConsortium, Dow, Goodrich, Baydur Adhesives

The objective of this effort is to develop experimentally-based, durability driven guidelines to assure the longterm environmental degradation, integrity of carbon-fiber-based polymeric composite automotive structures.

Keywords: Carbon-Fiber Reinforced Polymer MatrixComposites, Durability

33. USAMP COOPERATIVE AGREEMENT$6,300,000DOE Contact: Joseph Carpenter (202) 586-1022ORO Contact: Mary Rawlins (865) 576-0823University Partners: University of Tulsa, University

of Michigan, University of Santa Barbara,University of Cincinnati, Wayne State University,Stanford University, University of Nottingham.Industry Partners: US Automotive MaterialsPartnership (DaimlerChrysler, Ford, GM),Goodrich, Baydyr Adhesives, Dow,Westmoreland, EKK, Entelechy, AmericanFoundryman’s Society, Mascotech, StackpoleLtd., Valimet, Aluminum consultant’s Group

The objectives of this project are to define and conductvehicle related R&D in materials and materialsprocessing. Projects include: Structural Cast MagnesiumDevelopment, Development of Manufacturing Methods ofFiber Preforms, Composite Intensive Body StructureDevelopment, Crash Energy Management, High VolumeProcessing of Composites, Hydroforming of AluminumTubes, Adaptive Flexible Binder Control for RobustStamping of Aluminum Sheet, Long Life Electrodes forResistance Spot Welding of Aluminum Sheet Alloys andCoated High Strength Steels, Magnesium Powertrain DieCast Components, Plasma Arc Welding of LightweightMaterials, Warm Forming of Aluminum, High StrengthSteel Stamping (Springback Predictability) Hydroformingand Lubricants for High Strength Steels, Strain RateCharacterization of High Strength Steels, High StrengthSteel Tailor Welded Blanks. Projects are conducted bymulti-organizational teams involving USAMP members,automotive suppliers, universities and private researchinstitutions.

Keywords: Polymer Composites, Aluminum ,Magnesium, Fiber Preforming, AdhesiveBonding, Rapid Prototyping, High StrengthSteel, Forming, High Volume Processing,Stamping, Die Casting, Welding, SpotWelding

34. DEVELOPMENT OF LOW-COST CARBON FIBER$1,900,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Dave Warren (865) 574-9693Laboratory Partners: ORNLUniversity Partners: Clemson University, Virginia

Technological UniversityIndustry Partners: USAMP/Automotive Composites

Consortium, AKZO Fortafil Fibers, Amoco,Westvaco, Hexcel Corporation

The objective of this effort is to conduct materialsresearch to lead to the development of low cost carbonfiber for automotive applications. Research includesinvestigation of alternate energy deposition methods and


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alternate precursors for producing carbon fiber as well asthe development of improved thermal processingmethods and equipment for fiber manufacture. This workexamines the fiber architecture and manufacturing issuesassociated with carbon fiber usage to take advantage ofthe high strength and modulus of carbon fiber whileminimizing the effects of its low strain-to-failure. Theultimate goal of this effort is to reduce the cost ofcommodity grade carbon fiber to $3-5 per pound.

Keywords: Polymer Composites, Durability,Processing, Low Cost Carbon Fiber,Microwave Processing, Precursors.

35. RECYCLING$350,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069ANL Contact: George Fenske (630) 252-5190Laboratory Partners: ANLIndustry Partners: Vehicle Recycling Partnership

The objectives of this effort are: to investigate cost-effective technologies for recycling polymer composites;and to establish priorities for advanced recyclinginitiatives and provide technical oversight to ensure thatpriority goals and objectives are accomplished.

Keywords: Recycle, Polymer Composites

36. STRUCTURAL RELIABILITY OF LIGHTWEIGHTGLAZING ALTERNATIVES$350,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Phil Sklad (865) 574-5069PNNL Contact: M. A. Khaleel (509) 375-2438Laboratory Partners: PNNLIndustry Partners: Visteon

The objective of this effort is to develop advancednumerical modeling and simulation tools to evaluate thestructural reliability of lightweight thin glazing designs forautomotive applications.

Keywords: Glazing, Structural Reliability

37. HIGH RATE PROCESSING TECHNOLOGIES FORPOLYMER COMPOSITE MATERIALS$525,000DOE Contact: Joseph Carpenter (202) 586-1022ORNL Contact: Dave Warren (865) 574-9693PNL Contact: Mark Smith (509) 376-2847Laboratory Partners: ORNL, PNLIndustry Partners: USCAR (DaimlerChrysler, Ford,

General Motors), Delphi

The purpose of this effort is to develop technologies tocost effectively process composite materials intoautomotive components, integrate these technologiesinto demonstration projects that display cost effective useof composites that can be manufactured in automotivefactories, develop advanced vehicle system designsbased on composite materials to both define futureresearch needs and demonstrate the technical andeconomic viability of developing technologies.

Keywords: Automotive, Polymer Composites, HighRate Processing, Focal Project Design

HEAVY VEHICLE PROPULSION MATERIALS

38. SMART MATERIALS FOR FUEL SYSTEMACTUATORS$400,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832DDC Contact: Craig Savonen (313) 592-5315

The objective of this effort is to develop advanced dieselengine fuel injection systems based on smart materials,such as piezoelectrics. Advanced fuel systems maycontrol the fuel injection event such that severalcontrolled injections are made for each combustion cycle,thus facilitating the control of combustion to optimize theefficiency and emissions from the engine. The effortincludes fuel injector design and bench and enginetesting. The incremental performance advantages ofapplying advanced material actuation to either of thecandidate actuator systems will be quantitativelyevaluated by a combination of baseline experimentalresults, material characterization, and advanced electro-mechanical-hydraulic analysis.

Keywords: Fuel Systems, Piezoelectric Actuators

39. COST-EFFECTIVE SMART MATERIALS FORDIESEL ENGINE APPLICATIONS$300,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

Work performed in FY 2002 has involved modifyingcommercial PZT powders with chemical additives andattrition milling to allow sintering of the PZT materials


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between 900 and 950/C. These sintering temperaturesshould allow the use of silver interlayer electrodes in themultilayer actuators. The primary work in FY 2003 willfocus on making multilayer PZT stacks using innerelectrodes fabricated from silver or silver doped withother materials to adjust for thermal mismatch duringsintering. Other areas of keen interest are to strengthenand/or toughen PZT materials with nano-metal or ceramicadditives. Finally a test fixture will be fabricated tocompress and measure the stroke of PZT multiplayerparts that will be fabricated.

Keywords: Fuel Systems, Piezoelectric Actuators

40. MANUFACTURING TECHNOLOGY FOR CERMETCOMPONENTS$75,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832SIUC Contact: Dale Wittmer (618) 453-7006

The purpose of this work is to investigate the potential oflow-cost manufacturing processes for ceramic andcermet diesel engine components. The primary task is todevelop cost-effective processing, forming, and sinteringmethodologies for cermet and ceramic formulations usedby industrial engine manufacturers. During this fundingcycle, we will continue to use our low-pressure injectionmolder to form several batches of intermetallic bondedTiC. The formed cermets will then be sintered by bothcontinuous sintering at SIUC and by the V-LPHIPprocess at ORNL. We intend to continue this work to thepoint of being able to produce near net shape parts foruse in diesel engines.

Keywords: Cermets, Intermetallics, ManufacturingTechnology

41. INTERMETALLIC-BONDED CERMETS$100,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The goal of this task is to develop high strength, high toughnessmaterials that can be sintered to near-net-shape for dieselengine applications, specifically for fuel delivery systems andwear components (e.g., valve seats and turbochargercomponents). This will require materials which have a minimumhardness of 11 GPa and a thermal expansion coefficient of upto 12 x 10

-6//C for temperatures up to ~600/C to minimize

thermal mismatch with metallic alloys. The material should alsohave excellent corrosion resistance in a diesel engineenvironment, flexure strength in excess of 700 MPa, andfracture toughness > 10 MPa%m to ensure long term reliability.The material should also be compatible with metallic alloys andexhibit negligible wear in combination with them. Finally, thetotal material processing costs for these advanced materials

should be competitive with competing technologies such as TiNor other ceramic coatings on high-speed tool steels.

Keywords: Cermets, Intermetallics, Fuel Systems

42. HIGH-TOUGHNESS MATERIALS$300,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of the effort is to develop high toughnessmaterials that are also low cost. TiC-Ni3Al compositeshave shown a combination of superior physical propertiesand mechanical behavior using conventional powderprocessing methods. Previously, the general propertyenvelope has been studied and the compositions refined.Further processing studies are needed to examine lot-to-lot variation using statistically designed experiments,determine compaction behavior, assess dimensionalcontrol during sintering, identify suitable binders whichwill not add carbon ash during sintering, and develop aviable and cost-effective source of NiAl powder. Theproject activities will be in close association withCoorsTek Inc. (a parts supplier) for scale-up of theprocessing, and Cummins Engine Co. for rig testing offabricated parts.

Keywords: Cermets, NiAl, TiC

43. MATERIALS FOR EXHAUST AFTERTREATMENT $400,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832Caterpillar Contact: Lou Balmer (309) 578-4468

This program will cover the following technologies. 1.Lean-NOx Catalysis:Because of the inherently low hydrocarbon concentrationin diesel exhaust, any NOx reduction catalyst will requirethe addition of supplemental reductant to achieveperformance goals. From a diesel engine user’sstandpoint, the best reductant to use in conjunction withaftertreatment systems is diesel fuel. Therefore,emphasis will be placed on research and development oncatalyst aftertreatment technologies that can utilize dieselfuel as a reductant to reduce NOx including Lean-NOxand Plasma Assisted Catalysis technologies. 2. NOxSensor: In most aftertreatment strategies, multiple NOxsensors will be required to monitor exhaust NOx levels asan on-board diagnostic tool and to control theaftertreatment device/engine for maximum fuel efficiency.The research will continue to focus on improvingdurability and response time of current state of the artsensors, in particular, amperometric type sensors.Further research will focus on alternative technologies forsensing NOx in the diesel exhaust environment.

Keywords: NOx, SCR, Sensors, Exhaust Aftertreatment


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44. CATALYST CHARACTERIZATION$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832Cummins Contact: Roger England (812) 350-5246

In order to meet the 2007 emission requirements fordiesels, it will be necessary to have a catalyst system indiesel engines. Currently, no commercial technologiesare available to meet these standards. Consequently,Cummins Inc. is developing their own system and seeksthe assistance of Metals and Ceramics Division at theOak Ridge National Laboratory (ORNL) with its materialscharacterization effort. The purpose of this effort is toproduce a quantitative understanding of the process/product interdependence leading to catalyst systems withimproved final product quality, resulting in diesel emissionlevels that meet the 2007 emission requirements. In theFY02 effort, baseline characterizations were done toprovide reference points. The location and dispersion ofactive catalytic elements in the washcoat were verified,and the temperature dependence and thermal stability ofthe adsorbed species was determined.

Keywords: NOx, SCR, Sensors, Exhaust Aftertreatment

45. DIESEL ENGINE PARTICULATE FILTER$300,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832Cummins Contact: Randy Stafford (812) 377-3279

The objective of this effort is the development of a dieselengine exhaust particulate filter that will allow the 2007EPA emission requirements to be met while maintaining,or improving, the durability and fuel efficiency of theengine.

Keywords: Diesel Engine, Exhaust Emissions,Particulate Emissions

46. DEVELOPMENT OF NOX SENSORS FOR HEAVYVEHICLE APPLICATIONS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The NOx sensor is an enabling technology which willpromote the advancement of both lean burn gasolineengines and diesel engines by permitting improvedengine control, along with the mandated on-boarddiagnostics. This task seeks to develop catalyticallyselective electrodes that will facilitate the development ofsimple resistive-type (mixed potential) NOx and ammoniasensors. The research will follow the logical progressionfrom: the catalytic evaluation of mixed conducting oxidepowders; the evaluation of the kinetics at the surfaces ofthese materials under the influence of applied electric

potential; and finally, the development of low-cost,resistive sensors based on materials developed.

Keywords: Sensors, NOx, Exhaust Aftertreatment

47. FIELD EMISSION ANALYTICAL MICROSCOPYFOR CHARACTERIZATION OF CATALYSTMICROSTRUCTURES AND DEACTIVATIONMECHANISMS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of the research is to use analytical andhigh-resolution transmission electron microscopy (TEM)to characterize the microstructures of emission-controlcatalysts. Catalyst research places emphasis on relatingmicrostructural changes to performance of diesel NOx-reduction catalysts. This research is focused onunderstanding these changes through TEM studies ofexperimental catalyst materials reacted in an ex-situcatalyst reactor system especially constructed to allowappropriate control of the reaction conditions and thetransfer of the sample between reactor and microscope.A secondary objective is to gain a better understanding ofthe structures of catalytic materials starting from theatomic level, by studying model catalyst systemscomprising heavy metal species on oxide supports.

Keywords: TEM, Catalyst, Microstructure

48. ADVANCED MATERIALS FOR LIGHTWEIGHTVALVE TRAIN COMPONENTS$189,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832Caterpillar Contact: Mark Andrews (309) 578-3896

The Advanced Materials for Lightweight Valve TrainComponents Program plans to design and fabricateprototype engine valves from high temperature advancedmaterials. The design of these valves will be based onestablished probabilistic design methodologies (e.g.,NASA/CARES Life and Honeywell’s CERAMIC andERICA computer codes). The testing of the prototypevalves will be accomplished on an in-house designedvalve test rig.

Keywords: Valves, Diesel Engines, Life Prediction


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49. THICK THERMAL BARRIER COATINGS (TTBCs)FOR LOW EMISSION, HIGH EFFICIENCY DIESELENGINE COMPONENTS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832Caterpillar Contact: Brad Beardsley (309) 578-8514

Engine testing of thermal sprayed coatings hasdemonstrated that their use as thermal barriers and wearcoatings can reduce fuel consumption, reduce wear andreduce component temperatures. The durability ofthermal sprayed coatings, particularly thermal barriercoatings, remains as the major technical challenge totheir implementation in new engine designs. Newapproaches to coating design and fabrication will bedeveloped to aid in overcoming this technical hurdle. Newlaser technology of surface dimpling, cleaning and laserassisted spraying will be applied to enhance adherenceand increase coating strength. Refinements of currentseal coating technologies will be developed to furtherenhance the durability of the coating structure. Newquasi-crystalline materials will be evaluated as thermalbarrier coatings as well as wear coatings for ring and linerapplications and as low friction coatings for camshaftsand crankshafts. Plasma spraying, D-Gun and HVOFprocessing with new engineered powders will be used todevelop these new coatings.

Keywords: Thermal Barrier Coatings, TTBC, PlasmaSpraying

50. MECHANICAL CHARACTERIZATION $85,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832NCA&T Contact: Jag Sankar (336) 256-1151

This project consists of the following four parallel tasks:

Task 1 - Thermal Barrier Protective Surface Coating. Abasic scientific understanding of thermal barrierprotective surface coating (TBC) to promote high-temperature performance and the effects of surface flawsand oxidation at elevated temperatures for thesematerials shall be initiated and carried out.

Task 2 - Nano-engineered smart materials. Pulsed LaserDeposition (PLD) technique gives a unique approach indeveloping novel oxides. NCA&T is developing a novelsmart thin film processing method based upon pulsedlaser deposition to process nanocrystalline materials withaccurate size and interface control with improvedmechanical and magnetic properties. Processingparameters, structure /property correlation and change inmagnetic characteristics shall be investigated.

Task 3 - Solid Oxide Thin Films. Zirconium oxide hasbeen extensively used in tribological and thermal barriercoatings for many years. NCA&T shall continue todevelop a liquid fuel combustion CVD technique for solidoxide thin film deposition. The processing parametersshall be optimized for the system. We shall also conductresearch related to controlling grain size (nano to microngrain size) to observe the effects on fuel cell materialsproperty.

Task 4 - Property Characterization. Mechanical propertycharacterization through appropriate methods includingnanohardness technique and full range of microscopy(macro to atomic level) and fractography work shall be apart of all tasks discussed above.

Keywords: Thermal Barrier Coatings, Nano Materials,Thin Films, Fuel Cells

51. NDE OF DIESEL ENGINE COMPONENTS $200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832ANL Contact: Bill Ellingson (630) 252-5068

The purpose of this work is to characterize machiningdamage in structural ceramic valves for diesel enginesusing various nondestructive evaluation (NDE) methods.One primary NDE method to be addressed is elasticoptical scattering. The end target is to demonstrate thatdata produced by this method can be correlated todamage as well as used for predicting materialmicrostructural and mechanical properties. There arethree tasks to be carried out: 1) characterizesurface/subsurface defects and machining damage andcorrelate NDE data with mechanical properties forflexure-bar specimens of several silicon nitrides used forvalves; 2) assess/evaluate ceramic valves to be run in asingle cylinder test engine; and 3) evaluate surface-damage healing by laser glazing on machined surfaces.This proposed work is a cooperative program withCaterpillar Inc.

Keywords: NDE, Nondestructive Evaluation, CeramicValves

52. DURABILITY OF DIESEL ENGINE COMPONENTMATERIALS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of this effort is to enable the selection anddevelopment of durable, lower-friction moving parts indiesel engines for heavy vehicle propulsion systemsthrough the systematic evaluation of promising newmaterials, surface treatments, composites, and coatingtechnologies under component-specific conditions.


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Specifically, the approach involves test methoddevelopment, microstructural analysis, behavioralmapping, and modeling. In FY 2001, a test method wasdeveloped to study the friction and wear characteristics ofcandidate exhaust gas recirculation (EGR) systemmaterials. A series of carefully selected commercialalloys, ceramics, and experimental materials wereevaluated for their high-temperature scuffing behavior. InFY 2002, this effort was extended to include aninvestigation of the scuffing of fuel injector componentmaterials. Innovative testing techniques were developedto produce and measure the fine-scale surface damagethat is observed in diesel engine fuel system parts.

Keywords: Tribology, Friction and Wear, Scuffing

53. LIFE PREDICTION OF DIESEL ENGINECOMPONENTS $200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

There has been considerable interest in the extensivepotential use of advanced ceramics and intermetallicalloys for applications in advanced diesel engine systemsbecause of their superior thermomechanical properties atelevated temperatures. This interest has then focusedprimarily on research aimed at characterization anddesign methodology development (life prediction) foradvanced silicon nitride ceramics and TiAl alloys in orderto manufacture consistent and reliable complex-shapedcomponents for diesel engine applications. The validprediction of mechanical reliability and service life is aprerequisite for the successful implementation of theseadvanced materials as internal combustion enginecomponents. There are three primary goals of thisresearch project, which contribute toward successfulimplementation: the generation of mechanicalengineering database from ambient to high temperaturesof candidate advanced materials before and afterexposure to simulated engine environments; themicrostructural characterization of failure phenomena inthese advanced materials and components fabricatedfrom them; and the application and verification ofprobabilistic life prediction methods using diesel enginecomponents as test cases. For all three stages, resultswill be provided to both the material suppliers andcomponent end-users to refine and optimize theprocessing parameters to achieve consistent mechanicalreliability, and validate the probabilistic design and lifeprediction of engine components made from theseadvanced materials.

Keywords: Life Prediction, Mechanical Characterization

54. LOW-COST MANUFACTURING OF PRECISIONDIESEL ENGINE COMPONENTS$235,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

Cost-effective machining processes are needed toensure the widespread use of high-performancematerials in engine components. Such components aretypically made from ceramics, ceramic-composites, andintermetallic materials. ORNL has developedinstrumented systems for studying the fundamentals ofmachining processes needed to make precisioncomponents from these materials. In the past, emphasishas been placed on grinding, since this is usually theprocess of last resort for shaping difficult-to-machinematerials. However, because there is also a need toapply other machining processes such as such asturning, milling, and drilling to these advanced materials,we are expanding our capabilities to include theseprocesses. In addition, non-destructive inspectiontechniques are being developed to verify that mechanicalproperties are not being degraded by the machiningprocesses. These efforts are best accomplished byworking directly with engine manufacturers, suppliers,machine tool builders, and the academic community.

Keywords: Machining, Inspection, Grinding, Turning,Milling, Drilling

55. CYLINDRICAL WIRE EDM AND TEMPERATUREMEASUREMENT$75,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832N. C. State Contact: Albert Shih (919) 515-5260

Cost-effective machining of cermets is critical to promotethe application of this wear-resistant, difficult-to-machinematerial. The grinding temperature and temperaturedistribution inside a diesel exhaust filter duringregeneration are important to understand the conditionsand performance of the process. Titanium, anotherdifficult-to-machine material, has the potential to bewidely used as a lightweight material for transportationapplications, if machining costs to achieve the final shapecan be reduced. This research will explore the cylindricalwire electrical discharge machining (EDM) of cermets,investigate the infrared-based, non-contact temperaturemeasurement for grinding and diesel exhaust filter, andstudy the machining of titanium-based alloys.

Keywords: EDM, Temperature Measurement, Titanium


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56. DEVELOPMENT OF LOW-COST AUSTENITICSTAINLESS DIESEL ENGINE COMPONENTSWITH ENHANCED HIGH-TEMPERATURERELIABILITY$160,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of this work is to evaluate cast austeniticstainless steels as alternate materials for SiMo ductilecast iron currently used in many diesel engines forexhaust manifold and turbocharger housing components.Cast stainless steels must withstand prolonged exposureat temperatures of 750/C or above, as well as survive thesevere thermal cycling from such high-temperatures tonear room-temperature. This project has testedcommercially available cast alloys and has developedseveral new modified cast stainless steels withsignificantly enhanced performance relative to SiMo castiron. The ultimate objective is a high-performance,reliable, and cost-effective exhaust component material.

Keywords: Austenitic Stainless Steel, Ductile Cast Iron,Exhaust System

57. TiAl NANOLAMINATE COMPOSITES$100,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832LLNL Contact: Luke Hsuing

This research seeks to fabricate and design TiAl alloyswith desired microstructures and adequate alloyingcomposition for advanced Diesel engine applications. Theprimary goals are 1) to exploit thermomechanical (hotextrusion) processing technique to fabricate two-phaseTiAl alloys with refined lamellar microstructures, 2) toexperimentally verify microstructural stability and creepresistance of the alloys, and 3) to investigate fundamentalinterrelationships among microstructures, alloyingadditions, and creep properties of the alloys so as toachieve the desired performance of the alloys for high-temperature applications.

Keywords: Titanium, Titanium Aluminide, LamellarMicrostructure

58. SYNTHESIS OF POWDERS FOR TITANIUMCARBIDE/NICKEL ALUMINIDE CERMETS$75,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832U. Colorado Contact: Alan Weimer (303) 492-3759

The objectives of this project are: 1) to synthesizesubmicron TiC particles by rapid carbothermal reduction,and 2) to develop a better understanding of monolithic

nickel aluminide synthesis and the potential for in-situcomposite TiC/Ni3Al synthesis.

Preliminary work using a high-temperature,thermogravimetric analyzer has indicated that fine TiCpowders of high purity can be synthesized with fastkinetics, indicating that “rapid carbothermal reduction”(RCR) using a transport tube reactor may be feasible.Since RCR processing is a commercial process forproducing tungsten carbide (WC) and since the synthesisof TiC and WC are similar, the RCR synthesis route mayprovide the best opportunity for commercial high qualityTiC. Very little work has been done to understand thekinetics and effect of reactants on the synthesis of nickelaluminide (NiAl and Ni3Al) powders. In addition, it wouldbe desirable to utilize the exothermic heat of reactionfrom the nickel aluminide reaction to drive theendothermic carbothermal reduction synthesis of titaniumcarbide. The reactions will need to be compatible in termsof reaction rate and temperature. The temperature ofreaction, the purity and size of the starting reactants, andthe reactant composition will impact the reaction rate andquality of the products.

Keywords: Powder Synthesis, Titanium Carbide, NickelAluminide, Carbothermal Reduction

59. DIESEL EXHAUST GAS RECIRCULATIONCORROSION EFFECTS$50,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

In order to reduce NOx emissions, exhaust gasrecirculation (EGR) systems have been deployed indiesel engines. This approach reduces the peakcombustion temperatures and hence, NOx emissions.The use of EGR can lead to accelerated corrosion that isconsidered to be associated with the formation of sulfuricacid. While it has been observed that corrosion tends tofollow the dewpoints, there are indications of maxima incorrosion rates with dewpoint temperature. Two regimeshave been identified. The first regime is in thetemperature range between the dewpoints of the acidthat forms and that of water where strong acid is formed,and the second regime is below the water dewpointwhere very weak acid is formed. Both of these acidconcentrations, strong (50-70 percent) or very weak (500ppm), are very aggressive corrodents of the proposedmaterials of containment, aluminum and steel alloys. Theobjective of this task is to assess the effect of the variousoperating regimes controlled by engine parameters suchas fuel rate, fuel composition, EGR fraction, and enginecoolant temperature, on the corrosion rates of materials


37

of construction. The data and information generated willenhance materials selection.

Keywords: Corrosion, EGR

60. DURABILITY OF DIESEL ENGINE COMPONENTMATERIALS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of this effort is to support the developmentof durable, lower-friction moving parts in diesel enginesfor heavy vehicle propulsion systems through thesystematic evaluation of promising new materials,surface treatments, composites, and coating technologiesunder component-specific conditions. Emphasis is placedon parts that are subjected to high contact pressuresand/or operating temperatures, like fuel injector plungersand emissions control system components wherescuffing is a concern.

Keywords: Friction, Scuffing, Fuel Injectors

61. ROLLING CONTACT FATIGUE$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832NIST Contact: Said Jahanmir

During the coming year we will develop test methods forevaluating the contact damage behavior of ceramicsunder rolling and sliding conditions that simulate those ofcam roller followers, valves and valve seats. Therecommendations of the Contact Damage Working Groupmembers will guide our studies. We will involveinternational members through our participation in a newIEA Annex III. From the many recommendations of ourworking group, we will focus on two main areas:fundamental understanding of the nature of contactdamage in RCF and potential standardization of the 3-ball-on-rod RCF test. If sufficient technical interest andcapability exist, we will initiate a formal standarddevelopment.

Keywords: Contact Damage, IEA, Rolling ContactFatigue

62. IEA IMPLEMENTING AGREEMENT FOR APROGRAMME OF RESEARCH ANDDEVELOPMENT ON ADVANCED MATERIALSFOR TRANSPORTATION APPLICATIONS$200,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832

The objective of this project is the cooperativeassessment of new technologies for materials fabrication,

surface modification, and advanced materialscharacterization techniques of interest to thetransportation sector. The mechanisms for thiscooperative effort include information exchanges andjoint research tasks. Specific topics currently underconsideration are characterization of thin coatings forwear and thermal protection, contact damageassessment, development of materials for hydrogenstorage, and assessment of novel surface modificationtechniques for improved wear behavior. The activemembers in this IA are United States, Japan, andGermany.

Keywords: IEA, Materials Characterization

63. TESTING STANDARDS$100,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: D. R. Johnson (865) 576-6832NIST Contact: George Quinn (303) 492-3759

In FY 2002, work will focus on the following AmericanSociety of Testing and Materials and InternationalOrganization for Standards standards:

• Revisions will be completed on three ASTMstandards: Flexural Strength Standard C 1161,Fracture Toughness Standard C 1421 andFractographic Analysis Standard C 1322.

• The Surface Crack in Flexure (SCF) test method willbe completed as an ISO standard test.

• A first ballot draft of the new flexural strengthstandards for cylindrical rods will be completed.

Keywords: Standards, ASTM, Fracture Toughness,Flexural Strength

HIGH STRENGTH WEIGHT REDUCTION MATERIALS

64. DESIGN, ANALYSIS AND DEVELOPMENT OFLIGHTWEIGHT FRAMES FOR TRUCK AND BUSAPPLICATIONS$1,275,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNLIndustry Partners: Autokinetics, DaimlerChrysler,

Alcoa, Tower Automotive, Auto/SteelPartnership

The objective of this project is to develop concepts forlightweight frames for Class 1 and 2 trucks and buses,develop and implement low-cost manufacturingtechnologies, and validate concepts on full size vehicles.


38

Materials under consideration include aluminum, highstrength steels, MMCs and polymer matrix composites.

Keywords: Frames, Manufacturing, Lightweight,Trucks, Buses

65. DEVELOPMENT OF ADVANCED CASTINGTECHNOLOGIES FOR PRODUCTION OF HIGHINTEGRITY TRUCK COMPONENTS$800,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069PNNL Contact: Mark Smith (509) 376-2847Laboratory Partners: ORNL, PNNL, Albany

Research LabsIndustry Partners: Freightliner, PACCAR, Alcoa

The objectives of this project are: to develop andintegrate the necessary hardware and productionprocedures to implement advanced casting technologiesto a level capable of producing high-integrity parts atrates and volumes necessary for truck and automotiveapplications; to develop the necessary understanding andtechnology to cast large structural components for Class8 truck cabs; and to develop modeling and designcapabilities for optimizing steel castings for heavy vehicleapplications to reduce weight without sacrificingperformance.

Keywords: Aluminum Alloy, Casting, Truck,Automotive, Steel Castings

66. ADVANCED FORMING TECHNOLOGIES FORLIGHTWEIGHT ALLOYS$675,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: LANL, PNNL, INEEL, ORNL

The objective of this project is to evaluate new formingtechnologies for processing lightweight alloys, to use thenew process to achieve improved microstructure,properties, performance, and control in the production ofcomponents for heavy vehicles.

Keywords: Extrusion, Lightweight Alloys, Forming,Superplastic Forming, Magnesium,Aluminum

67. DEVELOPMENT OF CARBON MONLITHS FORSAFE, LOW PRESSURE ADSORPTIONSTORAGE AND RELEASE NATURAL GAS$600,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNL

The objective of this project is to develop and testmonolithic carbon adsorbant materials for the storage ofnatural gas in heavy vehicles. The goal is to develop theability to safely store and release sufficient natural gas atlow pressure (<1000psi) to power an urban delivery vanfor 80 miles.

Keywords: Natural Gas Storage, Carbon Monolith

68. IMPROVED MATERIALS FOR HEAVY VEHICLEBRAKE AND FRICTION APPLICATIONS$675,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNLIndustry Partners: Honeywell

The objective of these activities is to investigate thenature of changes on surfaces of materials duringbraking, develop understanding of the role of friction filmsin braking, to evaluate advanced materials for heavyvehicle brake application, and to develop reliable, cost-effective, laboratory-scale friction tests to select and ranknew materials and surface treatments for enginecomponents.

Keywords: Brakes, Friction Materials, Friction Films

69. HIGH CONDUCTIVITY CARBON FOAMS FORTHERMAL MANAGEMENT$125,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNL

The objective of this activity is to evaluate the use ofconductive carbon foam materials as a highly efficientand lightweight heat exchanger for heavy vehicle coolingneeds such as radiators, etc. Focus is on determiningbasic material properties, defining acceptable operatinglimits, and fabrication of the core structures which canoperate in a class 7-8 vehicle.

Keywords: Carbon Foam, Heat Exchanger, HeavyVehicle


39

70. ADVANCED JOINING TECHNOLOGYDEVELOPMENT$500,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ANL, ORNL, PNNL

The objective of this project is to develop cost-effectivetechnologies for joining lightweight materials as well asdissimilar materials for use in heavy vehicle structures.

Keywords: Friction Stir Processing, DissimilarMaterials, Joining

71. DEVELOPMENT OF ADVANCED MATERIALSFOR HEAVY VEHICLE APPLICATIONS$1,250,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ANL, NIST, ORNL, PNNL

The objective of this project is to evaluate advancedlightweight materials and processes that can potentiallyreduce weight or enhance the performance and durabilityof heavy vehicles. Materials that are being consideredinclude magnesium, titanium, metal matrix composites orcarbon fiber-reinforced polymer composites, as well asnon-conventional materials.

Keywords: Advanced Processes, Advanced Materials,Titanium, Magnesium, MMC

72. IMPLEMENTATION OF LIGHTWEIGHTMATERIALS IN HEAVY VEHICLE STRUCTURALAPPLICATIONS$2,470,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contacts: Phil Sklad (865) 574-5069 andDave Warren (865) 574-9693PNNL Contact: Mark Smith (509) 376- 2874Laboratory Partners: ORNL, PNNLIndustry Partners: Freightliner, PACCAR, Delphi,

Volvo

The objective of this project is to develop cost-effectivemanufacturing processes and design procedures forcarbon fiber reinforced composite materials, alone, ortogether with lightweight metals, for applications aimed atreducing the mass of Class 8 trucks to improve fueleconomy. Research efforts are concentrating on bothbody and frame members and emphasize the use of highperformance fibers embedded into commodity graderesin systems. Component and subsystem mass

reductions in excess of 50 percent is the goal of eachresearch effort.

Keywords: Carbon Fiber Reinforced Composites,Structural Components, PolymerProcessing, Magnesium

73. TECHNOLOGY ASSESSMENT AND EVALUATION$1,500,000DOE Contact: Sid Diamond (202) 586-8032ORNL Contact: Phil Sklad (865) 574-5069Laboratory Partners: ORNL

The objective of these activities is: to provide assessmentof various technologies, to conduct workshops to assesstechnology needs for the trucking industry, to developmulti-year program plans, and to provide guidance toprogram management as to appropriate investments forR&D funding, and to fund innovative research with smallbusinesses.

Keywords: Cost, Planning, Workshops, TechnicalManagement, Assessments

HIGH TEMPERATURE MATERIALS LABORATORY

74. HIGH TEMPERATURE MATERIALSLABORATORY USER PROGRAM$5,600,000DOE Contact: Sidney Diamond (202) 586-8032ORNL Contact: Arvid Pasto (865) 574-5123

The HTML (High Temperature Materials Laboratory) is anational user facility, offering opportunities for Americanindustries, universities and other federal agencies toperform in-depth characterization of advanced materialsunder the auspices of its User Program. Available areelectron microscopy for microstructural andmicrochemical analysis, equipment for measurement ofthe thermophysical and mechanical properties ofmaterials to elevated temperatures, X-ray and neutrondiffraction for structure and residual stress analysis, highspeed grinding machines and measurement ofcomponent shape, tolerances, surface finish and frictionand wear properties.

Keywords: Materials Characterization, Ceramics,Composites, Alloys, Components

Geothermal Technologies Program

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GEOTHERMAL TECHNOLOGIES PROGRAM

FY 2002

GEOTHERMAL TECHNOLOGIES PROGRAM - GRAND TOTAL $395,000

GEOTHERMAL MATERIALS $395,000

MATERIALS PROPERTIES, BEHAVIOR, CHARACTERIZATION OR TESTING $395,000

Non-Destructive Testing of Corrosion- and Erosion-Induced Damage in Geothermal Piping Systems 235,000

Structural Response Analysis for Well Cements 160,000


41

GEOTHERMAL TECHNOLOGIES PROGRAM

GEOTHERMAL MATERIALS

The primary goal of the geothermal materials program is to ensure that the private sector development of geothermal energyresources is not constrained by the availability of technologically and economically viable materials of construction. Thisrequires the performance of intermediate and long-term high-risk materials research and development.


75. NON-DESTRUCTIVE TESTING OFCORROSION- AND EROSION-INDUCEDDAMAGE IN GEOTHERMAL PIPING SYSTEMS$235,000DOE Contact: R. LaSala (202) 586-4198BNL Contacts: M.L. Berndt (631) 344-3060 and

A. J. Philippacopoulos (631) 344-6090

This project addresses the need for improvedinstrumentation and non-destructive testing (NDT) todetect corrosion and erosion-corrosion of geothermalpiping systems. Emphasis is placed on evaluating thesuitability of long-range NDT methods for on-lineinspection. The research involves: (a) theoreticalinvestigation of NDT methods as applied to specificproblems encountered in geothermal facilities; (b) fielddemonstration and evaluation of NDT methods withemphasis on on-line, long range techniques; and (c)integration of the results from NDT with remainingstrength and life assessment. Ultrasonic guided wavemethods have been identified as having the greatestpotential. Currently available guided wave systems fortesting piping use either a ring arrangement of multipledry coupled piezoelectric transducers clamped to theexternal pipe surface or a magnetostrictive sensor stripwrapped around the pipe. Piezoelectric transducers incurrent use have a temperature limitation ofapproximately 140°C (284°F) and, consequently, theirapplication to in geothermal piping is restricted torelatively low temperature conditions (i.e., injection pipingor during plant shutdown). The magnetostrictive systemhas greater range of application owing to its ability towithstand higher temperatures. In order to facilitate fieldimplementation, limited modeling studies were carriedout. The latter involved numerical evaluation of necessarydispersion relations for the propagation of elastic wavesin waveguides. Field demonstration of themagnetostrictive system is planned. The field tests willestablish the advantages, limitations and economicbenefit of implementing guided wave NDT in geothermalplants. Of specific interest is the inspection range for

pipes with different complexity as well as the impact ofdegree of scaling and presence of cement liners.

Keywords: Geothermal Piping, Non-DestructiveTesting, Corrosion, Plant Reliability,Ultrasonics, Guided Waves

76. STRUCTURAL RESPONSE ANALYSIS FORWELL CEMENTS$160,000DOE Contact: R. LaSala (202) 586-4198BNL Contacts: M.L. Berndt (631) 344-3060 and

A. J. Philippacopoulos (631) 344-6090

This project investigates the mechanical behavior ofgeothermal well cements. It employs detailedexperimental testing confirmed by numerical modeling ofthe structural response due to pressure and temperatureconditions. It is demonstrated that adequate materialscharacterization and selection of cements used for thecompletion of all types of wells (i.e., geothermal, oil andgas) must be based on rigorous structural analysis. Themodels used incorporate all major components, i.e.,casing-cement-formation so that all possible interactionsare accounted for during modeling. Furthermore, thisresearch shows that tensile strength is very critical for theperformance of the well. Consequently, enhancing thetensile strength of well cements is an important part ofthis program. Some of the fiber reinforced cements testedthus far appear very promising for enhancing tensilecapacity. Durability tests on fiber reinforced cementswere also performed to examine corrosion characteristicsand long term mechanical properties. In order to validatethe effectiveness of fiber reinforcement of well cements,several comparative evaluations were made between theresponse of fiber reinforced and conventional cements.Essentially, two fundamental types of failures are ofinterest, namely, tensile failure for weak far-field stressesand shear failure in the presence of compressive far-fieldstresses. Similarly, stresses due to local tectonic regimescan lead to debonding of the cement annulus from thesurrounding formation. The two fundamental failuremodes are being investigated to see their relevance tocement mechanical properties. Interface type potentialfailure conditions will be considered during future work.Meanwhile, tensile and shear failure conditions weremodeled by detailed finite element analysis. Thesenumerical evaluations utilize the descriptive materialmodels for fiber reinforced and lightweight cementsdetermined experimentally. There is an apparent need for


42

optimum cement formulations for all operating conditionsand any transient loadings experienced by the well duringits design life. This program will tackle these issues,including material behavior at elevated temperaturesassociated with geothermal wells.

Keywords: Geothermal Wells, Cements, MechanicalBehavior, Material Testing, FiberReinforcement, Structural Analysis, PTLoads

Hydrogen, Fuel Cells & Infrastructure Technologies Program

43

HYDROGEN, FUEL CELLS & INFRASTRUCTURE TECHNOLOGIES PROGRAM

FY 2002

HYDROGEN, FUEL CELLS & INFRASTRUCTURE TECHNOLOGIES PROGRAM - GRAND TOTAL $815,000

FUEL CELL MATERIALS PROGRAM $815,000

Carbon Composite Bipolar Plates for PEM Fuel Cells 200,000Cost-Effective Metallic Bipolar Plates Through Innovative Control of Surface Chemistry 200,000Nanopore Inorganic Membranes as Electrolytes in Fuel Cells 215,000Metallized Bacterial Cellulose Membranes in Fuel Cells 200,000


44

HYDROGEN, FUEL CELLS & INFRASTRUCTURE TECHNOLOGIES PROGRAM

FUEL CELL MATERIALS PROGRAM

77. CARBON COMPOSITE BIPOLAR PLATES FORPEM FUEL CELLS$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: T. M. Besmann

(865) 574-6852

The purpose of this work is to develop a slurry-moldedcarbon fiber material with a carbon chemical-vapor-infiltrated (CVI) sealed surface as a bipolar plate. Duringthis period thermal imaging was used to demonstrate flawidentification in composite material samples, significantsensitivity to delamination and surface roughnessillustrated. The Iosipescu torsion measurement methodwas used to determine the strength of the carboncomposite bipolar plate material under more realisticmechanical stress conditions. The results are indicativeof a relatively torsion resistant material, particularly giventhe low density of the carbon composite. The stress-displacement curves indicate little delamination or otherfailures until ultimate failure. A dramatic improvement inwetting of the carbon composite surface with an airoxidation treatment was demonstrated. Whereas prior tooxidative treatment water appeared to have a smallwetting angle on the surface of the carbon composite,after treatment water readily spread on the surface withan apparent large wetting angle. Efforts continue tosupport the licensee, Porvair Fuel Cell Materials, in theireffort to scale-up production.

Keywords: Bipolar Plates, Carbon Composites, FuelCells, Manufacturing

78. COST-EFFECTIVE METALLIC BIPOLARPLATES THROUGH INNOVATIVE CONTROLOF SURFACE CHEMISTRY$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: M. P. Brady

(865) 574-5153

The objective of this work is to develop a bipolar platealloy that will form an electrically conductive andcorrosion-resistant nitride surface layer during thermalnitridation. A model developmental nitrided Ni-50Cr wt.%alloy exhibited no discernible degradation after 1 weekimmersion in pH 2 sulfuric acid at 80°C and a corrosioncurrent density of less than 1 x 10-6 A/cm2 up to ~0.9V vsstandard hydrogen electrode (SHE) in pH 3 sulfuric acidat 80°C. A nitrided coupon of this material accumulated1800 h of exposure in the Los Alamos National Lab(LANL) Corrosion Test Cell (collaboration with K.

Weisbrod), with resistance increases of only0.5 mV/1000 h at the anode and 2mV/1000 h at thecathode (for comparison, 316 stainless steel exhibitsresistance increases of 16 and 21 mv/1000 h,respectively). Measurements at NREL (collaboration withH. Wang) showed that the nitridation treatmentsignificantly lowered contact resistance relative to theuntreated metallic alloy, and confirmed the excellentcorrosion resistance of the nitrided surface. Future workwill focus on in-cell evaluation of the model nitrided Ni-50Cr alloy to determine if the excellent corrosionresistance translates to acceptable in-cell performance,as well as reducing the level of Cr and Ni needed to yielda protective Cr-nitride layer in order to meet cost goals.

Keywords: Bipolar Plates, Coatings, CorrosionResistance, Fuel Cells, Nitride

79. NANOPORE INORGANIC MEMBRANES ASELECTROLYTES IN FUEL CELLS$215,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556U. of Wisconsin Contact: M. A. Anderson

(608) 262-2674

The objective of this work is to develop microporousinorganic oxide-based membranes of TiO2 with highproton conductivity that are capable of operating attemperatures above 100°C with minimal watermanagement problems. Inorganic PEMs represent afundamental departure from the polymer-based PEMscurrently used in hydrogen fuel cells. Therefore, fuel cellsbuilt using inorganic PEMs will require a significantlydifferent fabrication method. In particular, inorganic PEMsare not free standing, but rather need to be supported ona strong, porous substrate because the membranes areinherently ultra-thin and brittle. Inorganic membraneswere developed that demonstrated proton conductivity attemperatures up to 130°C at relative humidities of 81percent. In addition, a first-generation test apparatus wasfabricated to measure the performance of POEMs andMEAs containing POEMs in a functional fuel cellconfiguration.

Keywords: Fuel Cells, Inorganic Membranes, ProtonConductivity, PEM


45

80. METALLIZED BACTERIAL CELLULOSEMEMBRANES IN FUEL CELLS$200,000DOE Contact: N. L. Garland (202) 586-5673ORNL Contact: D. P. Stinton (865) 574-4556ORNL Principal Investigator: H. O’Neill

(865) 574-5004

The objective of this task is to develop low-cost bacterialcellulose membranes with high proton conductivity thatare capable of operating at above 120°C with minimalwater management problems. The present conceptproposes a cellulose matrix secreted by bacteria as asuitable material for PEM fuel cell technologydevelopment. The catalyst and electrolyte membranecomponents of the MEA are constructed using bacterialcellulose, underlining the multifunctional nature of thismaterial. The main impact, at the system level, of acellulose-based PEM fuel cell is that it will operate attemperatures near 130°C, circumventing the problemsassociated with Nafion-based PEM fuel cells. Severalstrategies were employed during the year to modifybacterial cellulose with ion-exchange groups. Modificationof the native bacterial cellulose with phosphate groupswas the most successful. Cellulose phosphate had a 2.7-fold greater thermal stability and a 7.6-fold low H2permeability than Nafion 117. Further characterization ofthis material is still required and will be carried out inconjunction with testing of the material in a membraneelectrode assembly.

Keywords: Fuel Cells, Membranes, Bacterial Cellulose,Water Management

Industrial Technologies Program

46

INDUSTRIAL TECHNOLOGIES PROGRAM

FY 2002

INDUSTRIAL TECHNOLOGIES PROGRAM - GRAND TOTAL $28,167,398

ALUMINUM VISION TEAM $10,874,792


Innovative Vertical Floatation Melter (VFM) 800,000Inert Metal Anode Life in Low Temperature Aluminum Reduction Process 1,190,000Intelligent Potroom Operation 583,000Development of a Novel Non-consumable Anode for Electrowinning Primary Aluminum 381,000Potlining Additives 493,000Reduction of Oxidative Melt Loss of Aluminum 531,000Selective Adsorption of Salts from Molten Aluminum 55,000Aluminum Carbothermic Technology 999,890Wetted Cathodes for Low Temperature Smelting 452,000High Efficiency Low Dross Combustion System 371,000A Bubble Probe for Optimization of Bubble Distribution and Minimization of Splashing/Droplet

Formation 100,000Microwave Assisted Electrolytic Cell 25,389

MATERIALS PROPERTIES, BEHAVIOR, CHARACTERIZATION OR TESTING $2,513,303

Integrated Numerical Methods and Design Provisions for Aluminum Structures 93,000Textures in Aluminum Alloys 308,000Reduction of Annealing Times for Energy Conservation in Aluminum Processing 80,000Surface Behavior of Aluminum Alloys Deformed under Various Processing Conditions 100,000Fundamental Studies of Structural Factors Affecting the Formability of Continuous Cast

Aluminum Alloys 100,000Development of a Two-phase Model for the Hot Deformation of Highly-Alloyed Aluminum 100,000Development of Integrated Methodology for Thermo-mechanical Processing of Aluminum Alloys 100,000Numerical Modeling of Transient Melt Flows and Interface Instability in Aluminum Reduction Cells 28,000Low Temperature Reduction of Alumina Using Fluorine Containing Ionic Liquids 28,000Effect of Impurities on the Processing of Aluminum Alloys in Casting, Extrusion, and Rolling 22,303Combined Experimental and Computational Approach for the Design of Mold Surface Topography 28,000Molten Aluminum Treatment by Salt Fluxing with Low Environmental Emissions 21,000Inert Metal Anodes for Primary Aluminum Production 220,000Improved Energy Efficiency in Aluminum Melting 765,000Evaluation and Characterization of In-Line Annealed Continuous Cast Aluminum Sheet 520,000

MATERIALS PREPARATION, SYNTHESIS, DEPOSITION, GROWTH OR FORMING $2,380,210

Processing and Recycling of Aluminum Wastes 111,000Wettable Ceramic-based Drained Cathode Technology for Aluminum Electrolysis Cells 720,000Spray Rolling Aluminum Strip 133,000Modeling Optimization of Direct Chill Casting 404,000Degassing of Aluminum Alloys Using Ultrasonic Vibrations 60,000Effect of Casting Conditions & Composition on Microstructural Gradients in Roll Cast

Aluminum Alloys 30,010Energy Efficient Isothermal Melting of Aluminum 479,000Coolant Characteristics and Control in Direct Chill Casting of Aluminum 130,000Continuous Severe Deformation Processing of Aluminum Alloys 300,000Development of a Rolling Process Design Tool for Use in Improving Hot Roll Slab Recovery 13,200


47

INDUSTRIAL TECHNOLOGIES PROGRAM (continued)

FY 2002

GLASS INDUSTRY OF THE FUTURE $200,000


Development of Models and On-line Diagnostic Monitors of the High-temperatureCorrosion of Refractories in Oxy-fuel Glass Furnaces 200,000

FOREST AND PAPER PRODUCTS $1,950,792

MATERIALS PREPARATION, SYNTHESIS, DEPOSITION, GROWTH OR FORMING $615,000

Particle Formation and Deposition in Recovery Boiler Applications 270,000Non-Process Element (NPE) Removal Using Functionalized Monolayers on

Mesoporous Supports 280,000Use of Residual Solids From Pulp and Paper Mills for Enhancing Strength and

Durability of Ready-Mixed Concrete 65,000


Corrosion in Kraft Digesters: Characterization and Evaluation of Corrosion Control Methods 599,542

Selection and Development of Refractory Structural Materials for Black LiquorGasification 200,000

Chromium Rich Alloys for Gasifier and Kraft Recovery Boiler Applications 247,500Ceramic Coatings for Use in High Temperature, High Pressure Black Liquor Gasifiers 288,750

METAL CASTING $1,403,000


Creep Resistant Zinc Alloy Development 132,000Development of Surface Engineered Coatings for Die Casting Dies 244,000Integration of RSP Tooling with Rapid Prototyping for Die-Casting Application 63,000


Clean Cast Steel: 1) Machinability of Cast Steel; 2) Accelerated Transfer ofClean Steel Technology 166,000

Prevention of Porosity in Iron Castings 47,000Advanced Lost Foam Casting Technology 218,000Metallic Reinforcement of Direct Squeeze Die Cast Aluminum Alloys 100,000Ferrite Measurements in Duplex Stainless Steel Castings 120,000Technology for the Production of Clean, Thin Wall, Machinable Gray and

Ductile Iron Castings 107,000Improvements in Sand Mold/Core Technology: Effects on Casting Finish 106,000Heat Checking and Washout of Superalloys for Die Inserts 100,000


48

INDUSTRIAL TECHNOLOGIES PROGRAM (continued)

FY 2002

INDUSTRIAL MATERIALS FOR THE FUTURE $13,738,814

MATERIALS PREPARATION, SYNTHESIS, DEPOSITION, GROWTH, OR FORMING $9,096,676

Advanced Materials/Processes 1,090,000Conducting Polymers: Synthesis and Industrial Applications 150,000Development of Advanced Metallic/intermetallic Alloys 670,000High Temperature Facilitated Membranes 350,000Intermetallic Alloy Development and Technology Transfer of Intermetallic Alloys 2,458,000Plasma Processing-Advanced Materials for Corrosion and Erosion Resistance 300,000Development of Ultrananocrystalline Diamond (UNCD) Coatings for SiC Multipurpose

Mechanical Pump 250,000Exploring Ultrahigh Magnetic Field Processing of Materials for Developing Customized

Microstructures and Enhanced Performance 200,000Inverse Process Analysis for the Acquisition of Accurate Thermophysical Data 250,000Development of Stronger and More Reliable Cast Austenitic Stainless Steels 300,000Ultrasonic Processing of Materials 150,000High Energy Density Coating of High Temperature Advanced Materials for Energy Efficient

Performance 150,000Novel Carbon Films for next Generation Rotating Equipment Applications 225,676Advanced Composite Coatings 300,000High-Density Infrared Surface Treatments of Refractories 200,000Development of a New Class of Ferritic Steels for Industrial Process Applications 500,000Crosscutting Industrial Applications of a New Class of Ultrahard Borides 245,000Development of Advanced Wear and Corrosion Resistant Systems Through Laser Surface

Alloying and Materials Simulation 170,000Development and Demonstration of Advanced Tooling Alloys for Molds and Dies 180,000Novel Superhard Materials and Nanostructured Diamond Composites 358,000Advanced Nanoporous Composite Materials for Industrial Heating Applications 300,000High Density Infrared (HDI) Transient Fused Coatings for Improved Wear and Corrosion Resistance 300,000


Materials Development for the Forest Products Industry 400,000Metals Processing Laboratory Users (MPLUS) Facility 1,000,000Development of Combinatorial Methods for Alloy Design and Optimization 200,000Stochastic Multi-Objective Optimization of Heat and Corrosion Resistant Alloy Properties 186,617Fracture Toughness and Strength in a New Class of Bainitic Chromium Tungsten Steels 124,000Characterization and Structural Modeling of Magnesia-alumina Spinel Refractories 300,565Thermochemical Models High-temperature Materials Processing and Corrosion 200,000Virtual Weld-Joint Design Integrating Advanced Materials and Processing Technologies 250,000Stress-Assisted Corrosion (SAC) in Boiler Tubes 276,000

MATERIALS STRUCTURE AND COMPOSITION $300,000

Development of Cost-effective Low Permeability Ceramic and Refractory Components for Aluminum Melting and Casting 300,000

DEVICE OR COMPONENT FABRICATION, BEHAVIOR OR TESTING $1,404 ,956

Continuous Fiber Ceramic Composites (CFCC) - Industrial Technologies 750,000Selective Inorganic Thin Films 250,000Physical and Numerical Analysis of Extrusion Process for Production of Bimetallic Tubes 200,000High Performance, Oxide Dispersion Strengthened Tubes for Production of Ethylene 204,956


49

INDUSTRIAL TECHNOLOGIES PROGRAM

ALUMINUM VISION TEAMThe DOE Aluminum Team leader is Tom Robinson(202) 586-0139


81. INNOVATIVE VERTICAL FLOATATION MELTER(VFM)$800,000DOE Contact: Tom Robinson (202) 586-0139

The Energy Research Company, O’Brien & GereEngineers, Inc., and Stein, Atkinson Stordy Ltd. areproject partners for the development of VFM. Recycledaluminum accounts for more than one third of the totalU.S. aluminum supply. Aluminum recycling results insignificant energy savings, lower emissions and anincrease in metal yield. Typically, aluminum scrap iscleaned/decoated and then melted in gas reverberatoryfurnaces that have low thermal efficiencies (20%) andgenerate substantial emissions. The vertical floatationmelter is an innovative design that decoats, preheats andmelts in one operation. The pilot demonstrated designprovides a thermal efficiency of 58%. Not only is energysaved, but also the emissions are significantly reducedand more metal is recovered. The design provides ahigher metal yield (dross reduction) because of lower gastemperature, lower residence time, lower oxygen contentand no direct flame impingement on the metal. The VFMis a versatile design that can be integrated with indirect-fired controlled-atmosphere rotating kilns. This integrationprovides additional savings, with thermal efficiencies ofover 75 percent in recovering aluminum scrap. Thisprocess also has applications in the glass and steelindustries. A pilot scale unit capable of processing 1,000pounds per hour of aluminum has been designed,constructed and successfully tested. Pilot operationshave demonstrated a thermal efficiency (the ratio of heatgoing into scrap aluminum to that of the total energyused) of more than 2.5 times that of a conventionalfurnace, lower emissions and improved metal recovery(dross reduced by more than half). This project has nowentered the planning, site preparation and field-testingphase that will demonstrate the VFM’s commercial use.

Keywords: Floatation Melter, Aluminum Scrap

82. INERT METAL ANODE LIFE IN LOWTEMPERATURE ALUMINUM REDUCTIONPROCESS$1,190,000DOE Contact: Tom Robinson (202) 586-0139

Northwest Aluminum Technologies and Brooks Rand,Ltd. are project partners for the development of thistechnology. A carbon-free aluminum reduction process isbeing developed as a modification to the Hall-Héroultprocess for primary aluminum production. The processuses a non-consumable metal alloy anode, a wettedcathode, and an electrolytic bath, which is kept saturatedwith alumina at the relatively low temperature of 750oC bymeans of free alumina particles suspended in the bath. Inconducting the research, two primary tasks are involved.First, laboratory scale cells will be operated to firmlyestablish the viability of the fundamental conceptsrequired for a successful commercial process. Second, apilot scale 5000-ampere cell will be designed, constructedand operated. This task will address engineering aspectsassociated with scaling, such as liner fabrication,electrode configuration and design, and bath compositionadjustments. This technology, once developed, willproduce primary aluminum metal with lower energyintensity, lower cost, and lower environmentaldegradation than the conventional process.

Keywords: Aluminum Reduction, Inert Metal Anode,Smelting, Alumina Crucible Cell, Voltage

83. INTELLIGENT POTROOM OPERATION$583,000DOE Contact: Tom Robinson (202) 586-0139

Applied Industrial Solutions, Century Aluminum, andWest Virginia University are project partners for thedevelopment of intelligent potroom operation. Aluminumsmelting requires operators to oversee many refiningcells. Scrutiny of each one on a regular basis is notpossible. In addition, modern aluminum refining cellcontrollers attempt to optimize cell efficiency bycontrolling the concentration of alumina in the bath.Unfortunately, no direct measure of aluminaconcentration is yet possible. The ramificationsmiscalculating alumina concentration is significant froman environmental and energy efficiency standpoint. Onemajor product of this research will be the development ofa Corrective Action Neural Network (CANN). Its functionis to monitor and analyze data from the pots on acontinuous basis, looking for cells whose performance isdeteriorating. It will anticipate which cells are about to slipinto degraded or out-of-control operation and dispatch theoperator to intervene before trouble begins. Eventually, aclosed-loop Cell Control Enhancement Module (CCEM)will be added to the individual cell controllers. The CCEM


50

will use an enhanced instrumentation package andpowerful data analysis techniques to provide a morecomplete picture of instantaneous cell status to theCANN. The CANN and CCEM will work in concert tocontinuously improve the database on each cell, and theknowledge base on control and remediation techniques.

Keywords: Smelting, Aluminum Potroom Operation,Aluminum Refining

84. DEVELOPMENT OF A NOVEL NON-CONSUMABLE ANODE FOR ELECTROWINNINGPRIMARY ALUMINUM$381,000DOE Contact: Tom Robinson (202) 586-0139

Ohio State University assisted by Gas Research Institute,Kaiser Aluminum, Siemens-Westinghouse and TDAResearch are project partners for the development of anovel non-consumable anode. Since the patenting of theHall-Héroult Cell (HHC) in 1886 for electrowinningaluminum, the basic features have remained essentiallythe same. Although significant optimization has occurred,industry acknowledges that there are many problemsassociated with the use of the consumable carbon anode.This project is developing a novel non-consumable (gas)anode that will displace today=s carbon anode(eliminating the carbon plant), and serve as a retrofit intothe current HHC. The anode is comprised of a thin,dense oxide-ion-conducting membrane with anelectrocatalytic porous internal anode where reformednatural gas is electrochemically oxidized. Application ofsuch a non-consumable anode retrofitted into the HHCwould significantly increase the energy efficiency, reducethe emissions, and reduce the cost of producing primaryaluminum compared to the best current and emerginganode replacement technologies.

Keywords: Carbon Anode, Aluminum Production,Smelting

85. POTLINING ADDITIVES$493,000DOE Contact: Tom Robinson (202) 586-0139

This project is designed to further examine the potentialbenefits derived from the addition of boron oxide topotlining used in primary aluminum production cells. Arelatively inexpensive bulk chemical, boron oxide not onlysuppresses cyanide formation, but also may inhibitsodium intercalation and, above all, promote, in thepresence of some titanium, wetting of cathodecarbonaceous material by the metal pad, thus reducingohmic cell resistance and sludge formation.Improvements in energy consumption, waste disposaland overall economics of the process are projected.Laboratory testing and commercial scale testing willinvestigate parameters that are important for the

commercial application. Tests in industrial cells willcomplement laboratory testing. Carbonaceous potliningcomponents added with boron oxide will be incorporatedin industrial cells in later phases of the program, providingresults of the first year are positive. Project partnersinclude Century Aluminum of West Virginia, Inc., EMECConsultants, the NSA Division of Southwire Companyand SGL Carbon Corporation.

Keywords: Potlining, Smelting, Aluminum Production,Boron Oxide, Aluminum Production Cells

86. REDUCTION OF OXIDATIVE MELT LOSS OFALUMINUM$531,000DOE Contact: Tom Robinson (202) 586-0139

Fabrication of virtually all finished aluminum productsrequires melting. During the melting process, an averageof 4 percent of the input material is lost to oxidation. Thelost material takes three forms in the furnace: 1) dross, amixture of aluminum oxide compounds and aluminummetal typically skimmed from the surface of the melt; 2)inclusions entrained in the molten metal removed byfiltration; and 3) oxide sludge found at the bottom of themelt. In the U.S., an annual energy loss of approximately70 trillion Btu results from oxidative melt loss of over 960million pounds of aluminum. This project will targetpractices to significantly reduce these losses. The meltloss project will identify aluminum melting practices thatwill increase energy efficiency and decrease materiallosses. The project will lower the cost of aluminumproducts, reduce energy consumption, reduce industrialemissions, and significantly increase the recyclingcapability of the aluminum industry. An increasedfundamental understanding of the oxidation of moltenaluminum will be developed to be a cross-section of thealuminum industry. Project partners include Secat, Inc.,Commonwealth Aluminum, Hydro Aluminum, IMCORecycling Inc., NSA Division of Southwire Co., AlcanAluminum Corp., ARCO Aluminum Inc., McCook MetalsLLC, Albany Research Co., Argonne National Laboratory,Oak Ridge National Laboratory, and University ofKentucky.

Keywords: Dross, Aluminum Melting, Oxide Sludge

87. SELECTIVE ADSORPTION OF SALTS FROMMOLTEN ALUMINUM$55,000DOE Contact: Tom Robinson (202) 586-0139

Selee Corp. and Alcoa are project partners for thedevelopment of this Selective Adsorption technology.Primary aluminum is produced by the reduction ofalumina in electrolytic cells. Cells contain a moltencryolite bath in which the alumina is dissolved. When anelectric current is applied, aluminum is released and


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settles to the bottom of the cell. Molten aluminum iswithdrawn to holding furnaces, and alumina is added tothe bath as it is consumed. In normal production, a smallportion of the bath is carried over with the moltenaluminum. Most of the bath carry-over can be removedby careful skimming and good transfer practices.However, some carry-over of the bath to the metalholding furnace is common. Cryolite bath containssodium and small amounts of calcium and lithium. Thesemetal salts must be removed from aluminum in theholding furnace to produce metal of commercial value.Chlorine is used to remove these salts. Bath carry-over isundesirable because it adds significantly to the timerequired and the amount of chlorine used to makecommercial aluminum. A new microporous material hasbeen demonstrated to selectively adsorb salts frommolten aluminum in holding furnace operations. Thisproject will evaluate the potential of adapting thesemicroporous materials to remove carry-over salts.Successful removal of these salts will result in significantreductions of energy, chlorine and metal loss.

Keywords: Alumina, Microporous Materials, Cryolite,Primary Aluminum

88. ALUMINUM CARBOTHERMIC TECHNOLOGY$999,890DOE Contact: Tom Robinson (202) 586-0139

Alcoa Technical Center, Elkem Aluminum Division, andCarnegie Mellon University are project partners for thedevelopment of the advanced reactor process (ARP).ARP is a new process for the production of aluminum bycarbothermic reduction. This technology has beenproposed as an alternative to the current Hall-Héroultelectrolytic reduction process. ARP has the potential toproduce primary aluminum at a power consumption in therange of 8.5 kWh/kg at an estimated 25 percent reductionin manufacturing cost. Although the carbothermic processinvolves the generation of carbon-based greenhousegases (GHG), the total GHG reduction from power plantto metal should be substantial due to the significantlyreduced power consumption, the elimination ofperfluorocarbon emissions, and the elimination of carbonanode baking furnace emissions. The estimated capitalinvestment required for ARP will be about 50 percent lessthan that for Hall-Héroult cell technology. The laborrequired for plant operation will also be reduced. ARP is amulti-step high temperature chemical reaction thatproduces aluminum by reduction of alumina with carbon.Optimization for reaction products requires a multi-zonefurnace operating at temperatures in excess of 2,000°C.A significant portion of the aluminum is in the gas phaseat these temperatures. A continuously operating furnacecapable of producing the high temperatures required andrecovering the molten and gas phase products is criticalfor the development of this technology. This is Phase I ofa multi-phase effort to develop an ACT reactor based on

advanced, high temperature, electric-arc furnacetechnology and improved understanding of the processreactions.

Keywords: Aluminum Carbothermic Reduction,Advanced Reactor Process, Alumina

89. WETTED CATHODES FOR LOW TEMPERATURESMELTING$452,000DOE Contact: Tom Robinson (202) 586-0139

Wetted cathodes and inert anodes have potentiallysignificant advantages over the century old Hall-Héroultcell used today for worldwide aluminum production.Wetted cathodes allow for decreased anode-cathodedistances accompanied by reduced voltages and energyconsumption. Inert anode replacement of conventionalcarbon anodes will eliminate the emission of greenhousegases associated with the production of primaryaluminum (e.g., CO, CO2 and perfluorocarbons) and withthe manufacture of the carbon anodes. The use ofwettable cathodes with inert anodes could reduce theenergy needed for primary aluminum production by 25 to30 percent. The adoption of these advanced electrodeshas been hindered by their rapid corrosion, particularly ofthe cathode, when operating at a conventionaltemperature of 950°C. A low temperature electrolysis(LTE) cell that operates about 200°C lower than aconventional cell offers a more benign environment foradvanced electrodes. This project will extend theknowledge of wetted cathode operation and failuremechanisms. It will prepare and screen various wettedcathode materials for aluminum LTE cells and developtechniques to measure and evaluate the aluminum filmon the wetted cathode. Successful development of thistechnology will lower both capital and operating costs andoffer many advantages in energy and environmentalconservation. Project partners include NorthwestAluminum Technologies, assisted by AdvancedRefractory Technologies, Material Modification Inc.,Electrochemical Technology Corp., Brooks Rand Limited,and Pacific Northwest National Laboratory.

Keywords: Low Temperature Electrolysis, Inert Anode,Wetted Cathode

90. HIGH EFFICIENCY LOW DROSS COMBUSTIONSYSTEM$371,000DOE Contact: Tom Robinson (202) 586-0139

Over 70 percent of 2.3 million tons of secondaryaluminum recovered from scrap is processed inreverberatory furnaces. These furnaces are widely usedbecause of their versatility and low capital cost. Despitetheir benefits, reverberatory furnaces exhibit unevensurface temperature and exposure to oxygen that


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promotes the production of dross on the surface of themolten aluminum. Dross formation lowers aluminumproductivity and insulates the molten aluminum therebylowering energy efficiency. This project will develop anddemonstrate a high-efficiency low-dross combustionsystem for secondary aluminum natural gas-firedreverberatory furnaces. Oxygen enrichment is key toimproving burner efficiency and has been demonstratedin many industries. Oxygen enriched flames are hotterthan air-fired flames and can promote dross formation.However, new burners and controls allow for the controlof the flame shape and distribution of oxygen within theflame. Controlling the flame with a fuel rich zone on theflame bottom ensures that the molten aluminum hasminimal exposure to oxygen and minimizes drossformation. At the same time, control of the flame shapeensures that the surface is evenly heated. Uponsuccessful completion, this project will decrease energyrequirements, improve economics, and decreasegaseous and solid emissions from the remelting ofaluminum. This technology can also be retrofitted toexisting reverberatory furnaces. Project partners includeGas Technology Institute, assisted by Wabash Alloys,LLC, Eclipse Combustion Inc., and University of IllinoisChicago.

Keywords: Reverberatory Furnace, Low-DrossCombustion, Secondary Aluminum

91. A BUBBLE PROBE FOR OPTIMIZATION OFBUBBLE DISTRIBUTION AND MINIMIZATION OFSPLASHING/ DROPLET FORMATION$100,000DOE Contact: Tom Robinson (202) 586-0139

Primary and secondary aluminum producers andfoundries remove impurities from molten aluminum bybubbling chlorine through the molten metal as a reactivefluxing gas. An example of chlorine fluxing is the removalof magnesium from close to 64 billion recycled aluminumcans (2 billion pounds of aluminum) to match the highpurity that is representative of aluminum produced fromelectrolytic cells. Primary aluminum producers also usegas fluxing to remove trace alkali metals from theelectrolyte present in the electrolytic cells. However,fluxing yields toxic gases such as hydrogen chloride andchlorine as well as aluminum oxide fumes. Chlorinebubbling is poorly controlled. Excess chlorine is used toensure impurities are reduced to acceptable levels, whichresults in both the loss of aluminum (AlCl3) and theemission of oxide fumes and toxic gases. Optimizingfluxing gas bubble size, frequency and residence time,and understanding how gas throughput may be increasedwithout splashing and spraying of molten metal as thebubbles burst at surface would substantially reducechlorine usage, increase productivity and thermalefficiency of aluminum purification process, and reduce

toxic gas emissions. Project partners include University ofCalifornia, Berkeley, assisted by Alcoa Technical Center.

Keywords: Gas Fluxing, Chlorine, Primary Aluminum

92. MICROWAVE ASSISTED ELECTROLYTIC CELL$25,389DOE Contact: Tom Robinson (202) 586-0139

This research is to develop a new electrometallurgicaltechnology by introducing microwave radiation into theelectrolytic cells for primary aluminum production.Michigan Technological University, collaborating withCober Electronic, Inc. and Century Aluminum Companywill provide technical, economic, and energy data forevaluation of this technology by conducting bench-scaleresearch. Controlling alumina solubility in the electrolyteis critical for low temperature operations. The proposedtechnology takes advantage of the microwave capabilityof increasing alumina solubility kinetics, so the reactioncan occur at lower operating temperature. The loweroperation temperature provides the possibility to use anickel-based superalloy for manufacturing the inert anodeand wetted cathode. The nickel-based superalloy is inertto oxidation at 750/ C, wetted with molten aluminum, andhas excellent salt corrosion resistance. The goal is todemonstrate the potential to enhance the electrolytic bathkinetics with microwave radiation to allow the use ofmaterials that have demonstrated good electrolyticinertness at lower temperatures.

Keywords: Alumina, Electrometallurgical, Microwave,Electrolytic Cells, Primary Aluminum


93. INTEGRATED NUMERICAL METHODS ANDDESIGN PROVISIONS FOR ALUMINUMSTRUCTURES$93,000DOE Contact: Tom Robinson (202) 586-0139

Project partners for this research effort are the AluminumAssociation and Cornell University. Aluminum’scompetitive edge arises from the ease with which shapescan be extruded. Yet, this advantage cannot be fullyexploited by designers because they do not have thetools to predict the strength of many extrudable shapes.Suggested specifications for the structural design of partsmade of various aluminum alloys were developed in 1962and published in 1967 in Specifications for AluminumStructures (Aluminum Association). The document hasbeen revised five times, most recently in 1994, butmethods for determining the buckling strength ofextrusions are essentially unchanged. Many types ofstiffeners, such as web stiffeners and multipleintermediate stiffeners, thickness changes and other


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cross-sectional peculiarities cannot be addressed by thecurrent specification even though they add significantly tothe load carrying capacity. Researchers from CornellUniversity will develop and demonstrate a designmethodology using finite strip analysis. It will result indesign rules applicable to many extrudable or cold-rolledshapes. Columns, beams, and beam columns will bestudied. A wide variety of failure modes such as local,distortional, torsional, torsional-flexural, and lateralbuckling will be researched. Failures involving theinteraction of these modes, such as the local and overallbuckling will be included in the study as well.

Keywords: Aluminum Extrusions, Aluminum Structures,Design Provisions

94. TEXTURES IN ALUMINUM ALLOYS$308,000DOE Contact: Tom Robinson (202) 586-0139

Aluminum sheets made by continuous strip castingprovide energy savings of greater than 26 percent andcost savings of more than 19 percent compared to sheetsmade from ingot casting and rolling. Sheet formability isamong the most important characteristics of aluminumsheet. Formability depends on the crystal grain structureand is a result of the casting method and processingsequences used to produce the sheet. The demand foraluminum sheets is increasing particularly in thetransportation industry where they are used to producelighter, more fuel-efficient vehicles. As more complexforms are required, improved process controls areneeded. Industry currently relies on post-processingtesting to determine formability characteristics of finishedsheet. The on-line monitoring of the continuously castsheet production process will allow simultaneous controlof important forming parameters. Crystallographic textureis related to the mechanical anisotropy/formability ofmetallic sheets. University of Kentucky andCommonwealth Aluminum will determine if there is aquantitative relationship between crystallographic texturemeasurements at processing temperatures andaluminum sheet formability. Data will be collected fromtwo different spectroscopic measuring devices. This datawill then be analyzed to determine if these instrumentscan produce measurements of the formabilitycharacteristics. The instrument proven to be mosteffective for measuring texture and formability atprocessing temperatures will be installed on-line in aproduction facility to demonstrate the ability to measureand control formability in continuous strip production.

Keywords: Textures in Aluminum Alloys,Crystallographic, Continuous Casting

95. REDUCTION OF ANNEALING TIMES FORENERGY CONSERVATION IN ALUMINUMPROCESSING$80,000DOE Contact: Tom Robinson (202) 586-0139

Annealing processes, in the early stages of aluminumprocessing, affect the structure and properties of thematerial. A necessary step in processing all direct chillingots is breakdown and hot rolling. In the typical single-stand mill, the time, temperature and deformationexperienced by material varies considerably and is highlyvariable with respect to location along the work piece andacross the section. Several large-volume, non-heattreatable aluminum alloys require one or more annealingsteps in order to recrystallize the material.Recrystallization requires long-range motion of grainboundaries to restore the mechanical state ready forfurther processing, or sale to customer. Althoughrecrystallization is a well understood process, very little isknown quantitatively about the influence of impurities andcrystallography on the critical process. The focus of thisresearch will be to measure these effects, relate them tothe actual compositions and deformation processing ofreal alloys and seek to minimize annealing times. Projectpartners will research how the annealing processes inearly stages of aluminum processing affect the structureand properties of the material. Annealing at hightemperatures consume significant amounts of time andenergy. By making detailed measurements of thecrystallography and morphology of internal structuralchanges, they expect to shorten processing times anduse less energy during annealing while improving texturecontrol in production of plate and sheet through a study ofthe kinetics of recrystallization in hot rolling. The researchwill exploit newly developed tools for textural andmicrostructural characterization to measurerecrystallization kinetics and texture evolution. Projectpartners include Carnegie Mellon University, assisted byAlcoa Technical Center and the PennsylvaniaTechnology Investment Authority.

Keywords: Annealing, Recrystallization, Hot Rolling

96. SURFACE BEHAVIOR OF ALUMINUM ALLOYSDEFORMED UNDER VARIOUS PROCESSINGCONDITIONS$100,000DOE Contact: Tom Robinson (202) 586-0139

Lehigh University and Alcoa Technology are projectpartners for establishing a relationship between surfacebehavior, metallurgy, and mechanical forming processparameters. Research will determine the fundamentalscontrolling surface microstructure development for rollingand extrusion processes. The objective is to understandthe origins and mechanisms of the formation of surfacephenomena including surface re-crystallization and


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surface fracture. Understanding the origins andmechanisms that control surface quality in formedaluminum products can help industry to reduce scrap,improve process efficiency, lower production costs, andsave energy. Formed products are produced by complexthermo-mechanical deformation operations such asrolling and extrusion. These metal-forming operations cancreate surface flaws which affect surface anodizing andcoating. Demand is rapidly growing for high qualityformed aluminum products in the automotive andaerospace industries. Surface quality is part of theformed aluminum product specifications and is ofcomparable importance to mechanical properties andalloy composition.

Keywords: Surface Behavior, Metallurgy, AluminumAlloys

97. FUNDAMENTAL STUDIES OF STRUCTURALFACTORS AFFECTING THE FORMABILITY OFCONTINUOUS CAST ALUMINUM ALLOYS$100,000DOE Contact: Tom Robinson (202) 586-0139

University of Kentucky is collaborating withCommonwealth Aluminum Company, Oak Ridge NationalLaboratory, and Secat, Incorporated in conducting thesestudies. Aluminum sheets made by continuous casting(CC) provide an energy savings of at least 25 percentand an economic savings of more than 14 percent oversheets made from direct chill (DC) cast ingots. Width andformability are among the most important characteristicsof aluminum sheets. There are substantial differences inthe microstructures of CC and DC cast sheets that are aresult of the casting process. Understanding themicrostructure differences and how these relate toproduct forming is required before industry will invest thelarge capital required for wide continuous cast sheetequipment. The ability to continuously cast wide sheetswith good formability microstructure will make the energyand economic savings available to a greater portion ofthe sheet forming market. The research will focus ondetermining the influence of the cast microstructure andthe spatial distribution of the intermetallic constituentsand dispersion phases of the microtexture duringdeformation and recrystallization. The object of thisresearch is to study in detail the difference in structurebetween DC and CC aluminum alloys that leads to thedifference in formability. This work will concentrate on the5000 series aluminum alloys, which have great potentialfor continuous cast product market growth. Thedifference in formability will be correlated with thedifference in bulk texture and microtexture of the twomaterials. The fundamental insight obtained from this

research will provide a science-based approach foroptimizing wide continuous casting technology.

Keywords: Continuous Casting, Microtexture, DirectChill Casting

98. DEVELOPMENT OF A TWO-PHASE MODEL FORTHE HOT DEFORMATION OF HIGHLY-ALLOYEDALUMINUM$100,000DOE Contact: Tom Robinson (202) 586-0139

Conventional processing methods for highly alloyedaluminum consist of ingot casting, followed by hot rolling.These alloys are susceptible to the development ofdefects in hot rolling, due to localized melting along thechemistry rich grain boundaries. Much energy is wastedthrough the need to re-melt and reprocess. For bothconventional hot rolling an novel processes such ascontinuous casting, quality will be achieved only throughunderstanding of the flow of the alloyed aluminum attemperatures approaching the melting point. Theresearch partners; University of Illinois, Alcoa, and LosAlamos National Laboratory, are developing afundamental understanding for deformation of wroughtalloys with emphasis on high temperatures bounding thehot working regime. Traditional constitutive modelsconsider the alloy as a single-phase system. Thisresearch is offering a plan that spans the identification offundamental deformation mechanisms using high-resolution electron microscopy and actualization intomodeling capability appropriate for industrial processes.This research is developing a two-phase mathematicaldescription for the high temperature flow of aluminumalloys. The focus is on hot rolling and provides acomputation platform for optimization of the Thermo-mechanical processing window (TPW) within industrialcapabilities of temperature and deformation rate. The keyresearch challenge is the formulation of robust relationsthat detail mechanical behavior in the presence of asemi-solid phase. Success in the research effort andsubsequent implementation in the domestic aluminumindustry would provide an energy savings, a carbondioxide reduction, a cost savings to the U.S. aluminumindustry, and a reduction in scrap.

Keywords: Ingot Casting, Hot Rolling, Aluminum Alloys

99. DEVELOPMENT OF INTEGRATEDMETHODOLOGY FOR THERMO-MECHANICALPROCESSING OF ALUMINUM ALLOYS$100,000DOE Contact: Tom Robinson (202) 586-0139

Washington State University, Alcoa Technology, andPacific Northwest National Laboratory are projectpartners for the development of the integratedmethodology for thermomechanical processing of


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aluminum alloys. The objective of this research is todevelop an integrated methodology for modeling localstructural evolution during thermomechanical processing(TMP) of rolled aluminum sheet for alloy design andmanufacturing. Current alloys and processes are over-engineered at a substantial energy and material cost toaluminum producers. Better understanding of the physicsof deformation and structure development will result inthe opportunity to reduce alloy content, minimizeprocessing steps, and improve performance of existingproducts. This research will involve developing a finiteelement based integrated mechanical and micro-structural model for process understanding and designsensitivity analyses and validating the integrated modelpredictions through bench-scale experimentalmeasurements. The ultimate goal is to produce modelsthat will allow simultaneous process modeling and alloydevelopment. The integrated model will enableresearchers to simultaneously address both materialsdynamics and mechanical behavior for alloy design andfor thermomechanical process optimization. The end-result will be processes optimized to reduce or eliminateenergy intensive batch anneals during processing ofautomotive sheet. The integrated model will involve bothlocal scale simulation of dislocation dynamics andmicrostructure evolution and macro-scale mechanicaldeformation simulations. The fundamental understandingand technology improvements derived from this researchwill translate into significant energy savings and greatfinancial and environmental benefits to the aluminumindustry.

Keywords: Thermomechanical Processing, AdvancedReactor Process, Alloys

100. NUMERICAL MODELING OF TRANSIENT MELTFLOWS AND INTERFACE INSTABILITY INALUMINUM REDUCTION CELLS$28,000DOE Contact: Tom Robinson (202) 586-0139

A key determinant in the energy consumption ofaluminum smelting pots is the magnetohydrodynamic(MHD) stability of the metal pad/electrolyte interface.More stable designs permit operation at lower anode-to-cathode spacing, thus decreasing power consumption.More stable MHD designs also control anode effectswhich contribute to lost productivity and release offluorine-based greenhouse gases. Incorporating newknowledge to allow better control of MHD effects inexisting and design retrofit plants in the domesticsmelting industry would decrease energy consumption.This research addresses the MHD induced melt flow andinterface instabilities in aluminum reduction cells. Thegoal is to develop a tool useful for the analysis of MHDinstabilities in smelting cells and then use it to gainunderstanding of the origin and nature of the MHDinstabilities. The partners will develop an accurate and

computationally efficient mathematical model that willincorporate substantially more relevant physics than theexisting models. In particular, the melt flows and interfaceinstability will be treated as coupled nonlinear nonsteadyprocesses. An accurate mathematical model will help toachieve more stable design of the reduction smelters.This will allow lowering the anode-to-cathode distance,thus reducing the energy consumption.

Keywords: Magnetohydrodynamic, Smelting, Alloys,Anode, Cathode

101. LOW-TEMPERATURE REDUCTION OFALUMINA USING FLUORINE CONTAININGIONIC LIQUIDS$28,000DOE Contact: Tom Robinson (202) 586-0139

No suitable substitute has been found for cryolite as amolten salt for the electrolytic reduction of aluminum,despite its high melting point. Cryolite's ability to dissolvealumina and its strong electrical conductivity has made itan inseparable part of the production of aluminum for thepast 100 years. However, recently developed ionic liquidsprovide a new promising possibility for aluminumproduction. Ionic liquids are salts that are fluid at roomtemperature. Chloride ionic liquids have already shownthe feasibility of reducing aluminum chlorides andfluoride-based ionic liquids can potentially be used todissolve and reduce alumina at room temperature.Research partners will investigate the potential for usingionic liquids as the electrolytes for the production ofprimary aluminum. The research will focus on identifyinga suitable ionic liquid that can be used for industrialelectrodeposition of aluminum at temperaturessignificantly lower than those encountered in the Hall-Héroult process. The effect and optimization of the mainelectrolytic parameters will be studied, and the results willbe compared with current technology. The fundamentalinsight obtained from this research will provide a science-based foundation for developing a process to producealuminum at low temperatures, thus increasing energysavings and lowering costs.

Keywords: Cryolite, Electrolytic Reduction, Ionic Liquid,Hall-Héroult Process

102. EFFECT OF IMPURITIES ON THE PROCESSINGOF ALUMINUM ALLOYS$22,303DOE Contact: Tom Robinson (202) 586-0139

Calcium, lithium and sodium are elements that areregarded as impurities in many aluminum alloys. Theimpurities contribute to the rejection rate of aluminumsheet and bar products. Rejected products must beremelted and recast. When products are remelted andrecast, a portion of the aluminum is lost to oxidation (melt


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loss). Removal of these elements increases overall meltloss of aluminum alloys. Project partners are investigatingthe effect of impurities on the processing of aluminumalloys with the aim of lower product rejection rates withthe resultant effect of lower melt losses. The goal of thisproject is to quantify the effect of impurities on theprocessing of multi-component aluminum alloys used incasting, extrusion, and rolling processes. Specificactivities include: 1) development of thermodynamic database on aluminum alloys containing Al, Na, Ca, Mg, andLi; 2) conduct computational thermodynamic simulationsto determine the phase equilibria of multi-componentalloys containing the impurity elements; 3) conduct kineticsimulations to determine the segregation behavior of theimpurity elements and their influence on the phaseevolution during processing conditions; and 4) verificationof results of simulations by conducting experiments underindustrial processing conditions.

Keywords: Alloys, Casting, Extrusion, Rolling,Thermodynamic, Oxidation, Melt Loss

103. COMBINED EXPERIMENTAL ANDCOMPUTATIONAL APPROACH FOR THEDESIGN OF MOLD SURFACE TOPOGRAPHY$28,000DOE Contact: Tom Robinson (202) 586-0139

One of the most challenging problems associated withmetal casting is the control of heat extraction through themold-shell interface during the early stages ofsolidification. This initial structure critically defines thedownstream performance of the cast product. Thisexperimental and computational effort is focused oninvestigating the effects of mold surface topography aswell as of the physical and thermal properties of the mold(such as wettability of molten aluminum over the moldsurface) on the geometric and physicochemical structureof the solidifying shell surface of aluminum castings. Thework will integrate heat transfer and deformation analysis;melt flow, contact modeling (tribology) as well asmetallurgical engineering. Finite element techniques willbe used to model the ingot surface growth and inversetechniques will be employed to design the mold surfacetopographies that lead to desired morphologies at thefreezing front surface. The mold surfaces will becharacterized in terms of groove taper, depth, pitch andland roughness.

Keywords: Mold Surface Topography, Casting, MeltFlow, Tribology

104. MOLTEN ALUMINUM TREATMENT BY SALTFLUXING WITH LOW ENVIRONMENTALEMISSIONS$21,000DOE Contact: Tom Robinson (202) 586-0139

Primary and secondary molten aluminum processing andrefining involve fluxing metal with either pure chlorine gasor chlorine and inert gas mixture. The stack emissionscaused by this gas injection include dust particles,hydrogen chloride, chlorine, and aluminum chloridegases. This research will investigate, understand, andminimize the emissions resulting from solid chloride fluxaddition to molten metal for alkali impurity andnonmetallic inclusion removal. Ohio State University willstudy the salt metal interactions and monitor theemissions at laboratory scale and Alcoa will verify thefindings on commercial scale. The goal is to obtain afundamental understanding, based on first principles, ofthe mechanisms for the pollutant formation that occurswhen the salts are used in furnaces. This mechanisticinformation will be used to control process parameters sothat emissions are consistently below the required levels.The information obtained in these experiments will be usefor developing mathematical models that will help inoptimizing the process.

Keywords: Salt Fluxing, Emissions, Primary Aluminum

105. INERT METAL ANODES FOR PRIMARYALUMINUM PRODUCTION$220,000DOE Contact: Tom Robinson (202) 586-0139

Project partners will investigate inert anode systems toidentify suitable candidate inert anode materials, testthese materials in alumina electrolysis cells, and conductpost-test analyses of the anode materials, bath, producedmetal, and cell hardware. Partners will focus on metalalloys as candidate materials, particularly alloys that formthin, self-limiting, self-healing alumina films. Selectionand identification of suitable alloys will occur bymeasurement of their aluminum diffusion rates, filmthickness, film dissolution rates, and thermodynamicproperties. Most past and present investigations of inertanodes have focused on using ceramics andceramic/metal materials. Metal anodes offer significantadvantages including improved electrical conductivity,fracture toughness, thermal shock resistance, eliminationof non-uniform current, and ease of fabrication intocomplex shapes for use in advanced cell designs.However, other than a few expensive noble metals,metals corrode in aluminum production cells. The projectpartners will develop a new inert hollow metal anode witha dissolving alumina surface film that is continuouslyreplenished by aluminum additions to the interior of theanode. The role of the surface film is to protect the metalfrom corroding. In this project, metal alloys that form thin,


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self-limiting, self-healing alumina films will be evaluatedfor this new design.

Keywords: Inert Anodes, Alumina Electrolysis Cells,Ceramics, Fracture Toughness

106. IMPROVED ENERGY EFFICIENCY INALUMINUM MELTING$765,000DOE Contact: Tom Robinson (202) 586-0139

Reverberatory furnaces are the principal means used formelting aluminum. Project partners will investigate threedimensional models, improved sensor and controlsystems, and improved insulation and refractorymaterials, to optimize the melting efficiency ofreverberatory furnaces (ERF) used for melting aluminum.An experimental ERF will be designed and built toconduct trials on combinations of oxy-fuel, stagedcombustion, new control systems, and new refractorymaterials and insulation. The most effective technologyimprovements will be demonstrated in cooperation withindustry partners.

Keywords: Reverberatory Furnaces, Sensor andControl, Aluminum Melting

107. EVALUATION AND CHARACTERIZATION OFIN-LINE ANNEALED CONTINUOUS CASTALUMINUM STEEL$520,000DOE Contact: Tom Robinson (202) 586-0139

For more than fifty years, the majority of aluminum strip,sheet and plate products have been produced bycombinations of hot and cold rolling and annealing oflarge ingots. In contrast, aluminum sheet made bycontinuous casting provides an energy savings of at least25 percent and an economic savings of more than 14percent over sheet products made from an ingot.Formability is among the most important characteristicsof aluminum sheet. Tensile and yield strength, ductility,and rates of work hardening control the complexity of theshapes that can be formed out of a sheet. Careful controlof the final microstructure, texture, and strengththroughout the sheet is required to give it good formingproperties. Continuous cast aluminum sheet is directlycast, hot rolled and coiled. The sheet is not homogenizedor held at a high temperature. This eliminates ordecreases chemical segregation within the sheet beforeor during hot rolling. This structure characteristic is veryimportant for aluminum alloys in subsequent processing.These alloys must have a uniform microstructurethroughout the sheet in order to achieve the desiredformability properties. The introduction of in-lineheating/annealing prior to coiling could ensure optimumsheet formability. This project will develop in-lineheating/annealing protocols for continuously cast

aluminum sheet prior to coiling. The focus is on utilizing aprocess optimization model and increasing theunderstanding of the evolution of microstructure andmicrotexture in continuously cast sheet during in-lineanneal. The implementation of this work will result in theproduction of continuous cast alloy sheet with improvedformability at high levels of productivity, consistency andquality.

Keywords: Casting, Microstructure, Alloys, Formability

MATERIALS PREPARATION, SYNTHESIS,DEPOSITION, GROWTH OR FORMING

108. PROCESSING AND RECYCLING OF ALUMINUMWASTES$111,000DOE Contact: Tom Robinson (202) 586-0139

This project at Michigan Technological University focuseson the development of a technology to divert the saltcake into valuable feedstock materials for themanufacturing of concrete products such as lightweightmasonry, foamed concrete, and mine backfill grouts. Byusing the unique properties inherent in the aluminum saltcake, this by-product can function as a foaming (airentraining) agent, and fine aggregate for use in concrete.The technology is expected to benefit the aluminum,concrete, mining and construction industries. Thealuminum industry will be able to increase its recovery ofaluminum metal while reducing energy consumption.Technology development objectives include:

• Process by-product waste streams from severalaluminum smelters and optimizes the processingrequired to convert wastes into products suitable foruse as concrete additives.

• Develop and demonstrate the processing requiredto effectively utilize the processed by-productsdeveloped for the production of mine backfill grouts.

• Develop and demonstrate the processing requiredfor lightweight aggregate/masonry block productionutilizing the processed by-products developed.

• Document the environmental acceptability of thesmelting by-products used as concrete additivesand assess the environmental acceptability of thelow-density concrete products made using theseadditives.

Keywords: Salt Cake, Recycling, Feedstock, WasteStreams, Concrete Additives


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109. WETTABLE CERAMIC-BASED DRAINEDCATHODE TECHNOLOGY FOR ALUMINUMELECTROLYSIS CELLS$720,000DOE Contact: Tom Robinson (202) 586-0139

Reynolds Metals Company, Kaiser Mead, and AdvancedRefractory Technologies (ART) will collaborate to developand evaluate ceramic-based materials, technology, andthe necessary engineering packages to retrofit existingreduction cells as a means to improve the performance ofthe Hall Héroult cell. ART will produce TiB2-based tiles orcoatings that will be used as the “drained” lining in two 70kA prebake cells. The durability of the candidatematerials and the performance of the drained cathodedesign will be evaluated during a one-month test using 12kA pilot reduction cells. This four-year project, initiated inSeptember 1997, will include the following activities:

• Development and evaluation of candidate TiB2carbon materials (tiles and coating)

• Development and evaluation of proprietary carbonmaterials

• Development of the drained cathode design• Evaluation of the best candidate materials and the

drained cathode design in the 12 kA pilot cell• Design and construction of a 70 kA prebake cell

retrofitted with a drained cathode using TiB2-basedand or the proprietary materials

• Startup and operation of two 70 kA prebake cellsretrofitted with a drained cathode and TiB2 and orthe proprietary materials

Keywords: Cathode, Aluminum Production, TitaniumDiboride

110. SPRAY ROLLING ALUMINUM STRIP$133,000DOE Contact: Tom Robinson (202) 586-0139INEEL Contact: Kevin McHugh (208) 525-5713

Alcoa Incorporated, Century Aluminum, Colorado Schoolof Mines, Idaho National Engineering and EnvironmentalLaboratory, Inductotherm, Metals Technology, andUniversity of California are project partners for thedevelopment of a new process that combines benefits oftwin-roll casting and spray forming. Aluminum’scompetitive edge arises from the ease with which shapescan be extruded. Nearly all aluminum strip ismanufactured commercially by conventional ingotmetallurgical (I/M) processing, also known as continuouscasting. This method accounts for about 70 percent ofdomestic production. However, it is energy and capitalequipment intensive. Spray forming is a competitive low-cost alternative to ingot metallurgy for manufacturingferrous and non-ferrous alloy shapes. It producesmaterials with a reduced number of processing steps,while maintaining materials properties, with the possibility

of near-net-shape manufacturing. However, there areseveral hurdles to large-scale commercial adoption ofspray forming: 1) ensuring strip is consistently flat, 2)eliminating porosity, particularly at the deposit/substrateinterface, and 3) improving material yield. Researchersare investigating a spray rolling approach to overcomethese hurdles. It should represent a processingimprovement over conventional spray forming for stripproduction. Spray rolling is an innovative manufacturingtechnique to produce aluminum net-shape products. Itrequires less energy and generates less scrap thanconventional processes and, consequently, enables thedevelopment of materials with lower environmentalimpacts in both processing and final products. Itcombines benefits of twin-roll casting and conventionalspray forming.

Keywords: Aluminum, Spray Forming, Aluminum Stripand Sheet

111. MODELING OPTIMIZATION OF DIRECT CHILLCASTING$404,000DOE Contact: Tom Robinson (202) 586-0139

The direct chill (DC) casting process is used for 68percent of the aluminum ingots produced in the U.S.Ingot scrap from stress cracks and butt deformationaccount for a 5 percent loss in production. The basicprocess of DC casting is straightforward. However, theinteraction of process variables is too complex to analyzeby intuition or practical experience. The industry ismoving toward larger ingot cross-sections, higher castingspeeds, and an increasing array of mold technologies toincrease overall productivity. Control of scrap levels isimportant in terms of both energy usage and costsavings. Predictive modeling and increasing the generalknowledge of the interaction effects should lowerproduction losses to 2 percent. This reduction in scrapcould result nationally in an estimated annual energysavings of over six trillion Btu and cost savings of over$550 million by 2020. The DC casting model projectfocuses on developing a detailed model of heatconditions, microstructure evolution, solidification,strain/stress development, and crack formation during DCcasting of aluminum. This model will provide insights intothe mechanisms of crack formation, butt deformation, andaid in optimizing DC process parameters and ingotgeometry. Project partners include Secat Inc., assisted byAlcan Aluminum Corp., ARCO Aluminum Inc., LoganAluminum Inc., McCook Metals, LCC, Wagstaff Inc.,Albany Research Co., Argonne National Laboratory, OakRidge National Laboratory, and University of Kentucky.

Keywords: Aluminum Ingot, Direct Chill Casting,Aluminum Scrap


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112. DEGASSING OF ALUMINUM ALLOYS USINGULTRASONIC VIBRATIONS$60,000DOE Contact: Tom Robinson (202) 586-0139

The goal of this research is to understand fundamentallythe effect of ultrasonic energy on the degassing of liquidmetals and the development of practical approaches forthe ultrasonic degassing of alloys. The result of ultrasonicuse will be a degassing process in which less argon isneeded and less aluminum is exposed to the furnacegases. This saves energy by reducing aluminumoxidation and the energy needed for argon production.This research will evaluate core principles and establishquantitative bases for the ultrasonic degassing ofaluminum alloy melts, and demonstrate the application ofultrasonic processing during ingot casting and foundryshape casting. Important issues to be studied and solvedinclude the coupling of the ultrasonic transducer to themelt, the effective transmission and distribution ofultrasonic vibrations in the melt, ultrasonic vibrationintensity and frequency, and protection of the meltsurface. The research will develop laboratory scaleequipment for ultrasonic degassing, study the effect ofprocess parameters, and identify the range of applicableprocess parameters for commercial implementation of thetechnology.

Keywords: Ultrasonic, Degassing, Casting

113. EFFECT OF CASTING CONDITIONS ANDCOMPOSITION ON MICROSTRUCTURALGRADIENTS IN ROLL CAST ALUMINUMALLOYS$30,010DOE Contact: Tom Robinson (202) 586-0139

Continuous roll casting of low alloy or unalloyedaluminum has been well established for several decadesand has demonstrated energy savings of more than 25percent relative to ingot rolling. There is great interest inextending this technology to the higher alloy series suchas 5xxx and 6xxx to take advantage of the benefits of thisprocess in high alloy products. This research is acomprehensive investigation of the effect of roll castingprocess conditions on the microstructure properties ofrelatively highly alloyed aluminum. The studies willdetermine the relationships between roll casting processparameters and the resulting microstructure, annealingresponse, and properties. In particular, themicrostructural analysis will investigate the nature of themicrostructural gradients that occur in these materialsand the influence of these structures on recrystallizationresponse, crystallographic texture, and formation ofcracks during forming. The combined effects of alloying

level and casting parameters on the resultant materialswill be modeled.

Keywords: Microstructural, Alloys, Casting, Annealing

114. ENERGY EFFICIENT ISOTHERMAL MELTINGOF ALUMINUM$479,000DOE Contact: Tom Robinson (202) 586-0139

The isothermal melting process (ITM) process saves halfthe energy and emissions associated with conventionalmelting. New materials and construction techniques forimmersion heaters make ITM practical for large scalealuminum operations. Project partners will demonstrateITM on a technically and commercially viable scale.Tasks include optimization of an immersion heater withcomposite refractory coating, design, construction anddemonstration of a heating and charging chamber, andsystem integration and performance assessment atcommercial scale. ITM will be implemented anddemonstrated at a commercial aluminum casting facility.

Keywords: Isothermal Melting Process, ImmersionHeater, Refractory

115. COOLANT CHARACTERISTICS AND CONTROLIN DIRECT CHILL CASTINGS OF ALUMINUM$130,000DOE Contact: Tom Robinson (202) 586-0139

Direct Chill (DC) casting is a critical process in theproduction of aluminum ingots. It is a casting process inwhich water-cooled molds initiate the first part ofsolidification. Thereafter, water sprays impinge on theshell of solid aluminum enclosing the liquid core. Toobtain higher productivity and better quality products, it isimportant to precisely control the cooling rate in DCcasting. Current methods of controlling the ingot coolingrate are empirical. A theoretical model based on systemparameters and coolant characteristics has not beenestablished. The cooling rate has a strong influence onthe temperature, strain, and stress field in the castproduct. A higher cooling rate can lead to higher thermalstresses and strains causing hot tearing and ingotcracking. This project focuses on understanding thefundamentals of coolant behavior and developingstrategies to control the cooling rate of DC casting ofaluminum ingots. Project partners will conduct afundamental study to identify various parametersaffecting critical heat flux and boiling transition andevaluate the effects of various additives (impurityparticulates, sodium and calcium salts, carbonates,bicarbonates, surfactants, etc.). Partners will also studythe effect of water quality on the ingot-cracking tendency.The research results are expected to guide coolingstrategies, which can then control metallurgical


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characteristics and mechanical properties. This will resultin better ingot yield from existing DC casting practices.

Keywords: Direct Chill Casting, Coolant Behavior

116. CONTINUOUS SEVERE PLASTICDEFORMATION PROCESSING OF ALUMINUMALLOYS$300,000DOE Contact: Tom Robinson (202) 586-0139

Ultrafine grained material allows the design andmanufacture of aluminum components that use lessmetal and require fewer manufacturing steps. Thisprovides energy and manufacturing cost savings. Severaltechniques for producing ultrafine grained materials arecurrently being investigated. These techniques are limitedin their ability to produce the size and quantities ofmaterial needed for commercial use. One technique toproduce ultrafine grained materials is the Equal ChannelAngular Extrusion (ECAE) process. This technique is amulti-step batch process that produces small cross-section, short-length stock, which severely limits itscommercialization. The Continuous Severe PlasticDeformation (CSPD) process will overcome thelimitations of ECAE by producing large cross-section,continuous length stock. Project partners will develop theCSPD process for the production of continuous longlengths of bulk ultrafine grained aluminum alloys.Partners will demonstrate its feasibility in the laboratoryand also demonstrate the advantages and use of theultrafine grained material under industrial conditions.Using the CSPD process in place of conventionalprocesses, and during secondary and finishingoperations, will provide significant energy and costbenefits.

Keywords: Plastic Deformation, Ultrafine GrainedMaterial

117. DEVELOPMENT OF A ROLLING PROCESSDESIGN TOOL FOR USE IN IMPROVING HOTROLL SLAB YIELD$13,200DOE Contact: Tom Robinson (202) 586-0139

Multiple passes in a reversing rolling mill of a hot slab areused to produce semi finished aluminum plate. However,the large deformations encountered while rolling maylead to failure modes that result in loss of part or even theentire slab. The formation of defects within the plate,such as edge cracking, delamination, alligatoring (centersplitting near the front and rear), and the formation ofundesirable rolled end shapes, all lead to product losses.Critical equipment downtime is also associated withseveral failure modes. Typically, rolling plant yield fromingot to final production is about 50 percent. Rejectedmaterial is recycled and melted to form new ingots.

Improving yield would lower the overall energy used inprocessing aluminum. The project goal is to develop anumerical modeling capability to optimize the hot rollingprocess used to produce aluminum plate. This tool will beused in the forming process so that loss of product will beminimized. Product lost in the rolling process requires theenergy-intensive steps of remelting and reforming into aningot. The modeling capability developed by projectpartners will be used to produce plate more efficientlyand with better properties.

Keywords: Plastic Deformation, Ultrafine GrainedMaterial

GLASS INDUSTRY OF THE FUTURE

Energy expenditures account for nearly 15 percent of theproduction costs of glass products. The Glass Industry ofthe Future program works closely with the U.S. glassindustry and other stakeholders to maintain a well-balanced portfolio of projects and services aimed atimproving the performance of glass manufacturingfacilities. Collaborative teams from industry, nationallaboratories, suppliers, universities, and otherorganizations share the risk and cost of R&D projects thatare awarded from a competitive solicitation process. TheDOE program manager is Elliott Levine (202) 5861476.


118. DEVELOPMENT OF MODELS AND ON-LINEDIAGNOSTIC MONITORS OF THE HIGH-TEMPERATURE CORROSION OFREFRACTORIES IN OXY-FUEL GLASSFURNACES$200,000DOE Contact: Mike Soboroff (202) 586-4936SNL Contact: Mark Allendorf (925) 294-2895

This research is directed toward understanding themechanism(s) of enhanced refractory corrosion in oxy-fuel glass furnaces and the development of models topredict corrosion rates, identify operating regimes thatminimize corrosion, and define the attributes of improvedrefractories. Activities in FY02 centered on conversion ofanalytical models to a software module for incorporationin a glass furnace code and field testing a monitor forgas-phase alkali detection.

Keywords: Refractories, Glass, Furnace, Oxy-Fuel,High Temperature, Properties, Corrosion,Monitor, Model


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FOREST AND PAPER PRODUCTS


119. PARTICLE FORMATION AND DEPOSITION INRECOVERY BOILER APPLICATIONS$270,000DOE Contact: David Boron (202) 586-0080SNL Contact: Christopher R. Shaddix

(925) 294-3840Brigham Young University Contact:

(801) 378-8616

The initial objective of this project was to measure therate of ash deposit accumulation, and the properties ofsuch deposits, under convection pass conditions in arecovery boiler. A follow-on objective is to quantify theconcentration of intermediate-size particles (ISPs)entrained in typical recovery boilers, identify themechanisms and rates of intermediate-size particleformation and deposition, and propose means ofcontrolling their impact on boiler operation. This is aseven-year project with an expected completion date ofSeptember 30, 2003.

Keywords: Deposition, Particle Formation, Recovery,Boilers

120. NON-PROCESS ELEMENT (NPE) REMOVALUSING FUNCTIONALIZED MONOLAYERS ONMESOPOROUS SUPPORTS$280,000DOE Contact: Dickson Ozokwelu (202) 586-8501PNNL Contact: Robert Leugemors

(509) 372-2814

The goal of this project is to develop extremely highcapacity, high selective sorbent materials to remove non-process elements (NPEs) from bleach cycle filtrate andfacilitate the partial or complete closure of the wastewater stream in modern kraft mill bleaching plants.Experiments will focus on the synthesis of functionalizedmesoporous materials (SAMMS) specifically designedto remove three general classes of NPEs: namelyalkaline earth cations (Ca, Ba, Mg), transition metalcations (Mn, Fe, Cu), and certain problematic anions(PO4, silicate aluminate, phenolate). This is a threeyear project with an expected completion date of September 30, 2002.

Keywords: Removal, Synthesis, Mesoporous Materials

121. USE OF RESIDUAL SOLIDS FROM PULP ANDPAPER MILLS FOR ENHANCING STRENGTHAND DURABILITY OF READY-MIXEDCONCRETE$65,000DOE Contact: Dickson Ozokwelu (202) 586-8501University of Wisconsin - Milwaukee Contact:

Tarun R. Naik (414) 299-6696

This project will develop a new type of ready-mixedconcrete using fibrous residuals from pulp and paper millprimary effluent sludge. The project will provide apractical solution to disposal problems for pulp and papermill byproducts and provide an economical source of fiberreinforcement for ready mixed concrete production. Thevarying lengths of fibers available from pulp and papermill sludge will help improve the tensile, flexural andcompressive strength of the concrete. This is a fouryear project with an expected completion date ofDecember 31, 2003.

Keywords: Pulp and Paper, Byproducts, Concrete


122. CORROSION IN KRAFT DIGESTERS:CHARACTERIZATION AND EVALUATION OFCORROSION CONTROL METHODS$599,542DOE Contact: David Boron (202) 586-0080ORNL Contact: James Keiser (865) 574-4453

This project will correlate chemical pulping digesterconditions with material performance. Digester conditionswill be evaluated using a computational fluid dynamicsmodel of flow with a digester. This flow model will besupplemented with a model for the chemical reactionsoccurring in the digester. In situ and laboratory corrosionstudies will be used to provide information about thecorrosion behavior of conventional materials. Anassessment of corrosion control methods and alternativematerials will be performed. This is a five-year projectwith an expected completion date of September 30,2003.

Keywords: Digester, Corrosion, Pulp and Paper

123. SELECTION AND DEVELOPMENT OFREFRACTORY STRUCTURAL MATERIALSFOR BLACK LIQUOR GASIFICATION$200,000DOE Contact: David Boron (202) 586-0080ORNL Contact: James Keiser (865) 574-4453

This project will identify refractory materials that haveacceptable life to allow gasifiers to effectively andeconomically operate using black liquor or biomass


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feedstocks. Working with industrial partners, theinvestigators will identify and address the most seriousmaterial problems associated with the top three emergingbiomass and black liquor gasification technologies.Studies will be performed to identify or develop moresuitable materials for these applications. This is a fouryear project with an expected completion date ofSeptember 30, 2003.

Keywords: Gasification, Black Liquor, Refractory, Pulpand Paper

124. CHROMIUM-RICH ALLOYS FOR GASIFIER ANDKRAFT RECOVERY BOILER APPLICATIONS$247,500DOE Contact: David Boron (202) 586-0080ORNL Contact: Micheal P. Brady (865) 574-5153

This project is an effort to develop a new family of moltensmelt resistant chromium-rich alloys with sufficientductility and toughness to permit use as structuralcomponents and/or coatings for gasifier and recoveryboiler applications. The project will significantly leverageexperience and laboratory scale molten salt testinginfrastructure gained in previous efforts for recoveryboiler materials and refractory materials for gasifiers. Thisis a three year project with an expected completion dateof September 30, 2004.

Keywords: Gasification, Recovery, Boilers

125. CERAMIC COATINGS FOR USE IN HIGHTEMPERATURE, HIGH PRESSURE BLACKLIQUOR GASIFIERS$288,750DOE Contact: David Boron (202) 586-0080ORNL Contact: James R. Keiser (865) 574 4453

The primary objective of this project is to identify at leastone ceramic/refractory material that has the appropriatethermal conductivity, smelt corrosion resistance andthermal shock resistance to serve as a thermal andchemical protective layer on a water-cooled metal tube ina high-temperature, high-pressure black liquor gasifier.Alternatively, if it can be demonstrated that a metal tubecan be fabricated that is resistant to this environment,then that formation will be provided to the designers. Ineither case, this constraint on gasifier development wouldbe eliminated. This is a three year project with anexpected completion date of 9/30/04

Keywords: Ceramics, Refractory, Black Liquor,Gasification

METAL CASTING


126. CREEP RESISTANT ZINC ALLOYDEVELOPMENT$132,000DOE Contact: Ehr Ping HuangFu (202) 586-1493International Lead Zinc Research Organization

Contact: Frank Goodwin (919) 361-4647

The objective of this project is to develop a hot chambercastable zinc die casting alloys that is capable ofsatisfactory service at 1400°C and preferably atmoderately elevated temperatures 160°C. The targetstrength at this temperature is 4,500psi during anexposure time of 1,000 hours. The project will beaccomplished by enhancing a previously existingcomputer model relating zinc alloy composition to creepstrength, followed by preparation of selected zinc diecasting metal alloys and pressure die casting of thesealloys. Mechanical testing will be carried out. Anoptimization task will then be conducted and these alloyswill then be characterized in a manner similar to the firstgroup of alloys. This task will be followed by technologytransfer to die casters and their customers, concerningproperties and processing of these enhanced alloys. Keywords: Zinc Alloys, Zinc Die Casting, Creep

Resistant

127. DEVELOPMENT OF SURFACE ENGINEEREDCOATINGS FOR DIE CASTING DIES$244,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Colorado School of Mines Contact: John Moore

(303) 273-3770

The objective of this research project is to develop acoating system that minimizes premature die failure (heatchecking, erosive, and corrosive heat), and extend dielife. No single (monolithic) coating is likely to provide theoptimum system for any specific die casting applicationthat will require its own specially designed "coatingsystem". An optimized coating system will require a multi-layer "architecture" within which each layer provides aspecific function, e.g., adhesion to the substrate,accommodation of thermal and residual stresses, wearand corrosion/oxidation resistance and non-wettabilitywith the molten metal. The initial research project willconcentrate on developing a coating system for dies usedin die casting aluminum alloys. The measured outcomesfrom this research program will quantify comparisons ofcurrent aluminum die casting practice with the measuredresults using the newly developed coating systems. Acomparison of cost/performance will also be determined


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for the new coating systems using current cost data asthe base line.

Keywords: Surface Coatings, Multi-Layered-SurfaceCoatings, Die Casting, Die Casting Dies

128. INTEGRATION OF RSP TOOLING WITH RAPIDPROTOTYPING FOR DIE-CASTINGAPPLICATION$63,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Colorado State University Contact:

James Folkstead (970) 491-7823

The objective of the project is to utilize a rapid-toolingtechnology that will reduce the lead time for prototypeand production die-casting tooling starting from a CADdrawing. Currently, there is no commercially availablerapid tooling technology that satisfies the needs of the diecasting industry. Compared to rapid tooling technologiesfor plastic injection molding and other plastic formingmethods, rapid tooling options for die casting are verylimited.

Keywords: Metalcasting, Die Casting, Rapid Tooling


129. CLEAN CAST STEEL: 1) MACHINABILITY OFCAST STEEL; 2) ACCELERATED TRANSFER OFCLEAN STEEL TECHNOLOGY$166,000DOE Contact: Ehr Ping HuangFu (202) 586-1493University of Alabama - Birmingham Contact:

Charles Bates (205) 975-8011

This project is an extension to the Clean Cast Steelproject, with the goal to improve casting product qualityby removing or minimizing oxide defects and allowing theproduction of higher integrity castings for high speedmachining lines. There are two objectives in this project,with the first one to identify the metallurgical factorsinfluencing machinability of steel to gain an engineeringunderstanding of the mechanism. A series of tests ofcommercial parts from participating foundries will beperformed to evaluate the machinability. Factors to beexamined include furnace practice, deoxidation practice,calcium wire injection, and heat treatment. The secondobjective is to provide the steel foundry industry with thetechnical resources needed to implement clean cast steeltechnology. Keywords: Metalcasting, Steel Casting, Machinability

130. PREVENTION OF POROSITY IN IRONCASTINGS$47,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Climax Research Services Contact: James Lakin

(248) 960-4900, Ext. 210

The objective of this research project is to understandporosity formation in castings, to generate fundamentalmaterials data relevant to porosity formation, and todevelop a method by which metalcasters can predict theporosity problem and make the necessary adjustments toprevent it. This will be accomplished by developing anunderstanding of the mechanisms for pore formation incastings, and developing a model for the use of the metalcasting industry. This model will take into account all thefactors affecting porosity formation. This model will helpiron foundries to predict the conditions that are conduciveto porosity formation in castings, and to take measures toprevent porosity.

Keywords: Metalcasting, Cast Iron, Porosity

131. ADVANCED LOST FOAM CASTINGTECHNOLOGY$218,000DOE Contact: Ehr Ping HuangFu (202) 586-1493University of Alabama - Birmingham Contact:


The objective of this project is to advance the state of theart in Lost Foam Casting technology. It is being carriedout at the Lost Foam Technology Center at the Universityof Alabama at Birmingham. The project provides a meansfor designers, manufacturers, and purchasers/users ofcast metal parts to harvest the benefits of the lost foamprocess, and furnishes project participants the bestavailable technology. The current research focus is onthe general technical areas of casting dimensionalprecision and freedom from casting defects in aluminumand cast iron. Tasks include foam pyrolysis defects,coating technology, pattern materials and production,computational modeling, casting distortion, andtechnology transfer.

Keywords: Metalcasting, Lost Foam Casting

132. METALLIC REINFORCEMENT OF DIRECTSQUEEZE DIE CAST ALUMINUM ALLOYS$100,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Case Western Reserve University Contact:

Jack Wallace (216) 368-4222

The objectives of the project are to: 1) developcommercially feasible methods of reinforcing aluminumdie castings with strong, tough metal inserts, 2) selectaluminum alloys for the matrix and customize the type of


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insert depending on the application, 3) optimize interfacialcoatings to provide a strong metallurgical bond betweenthe insert and aluminum alloy, and 4) evaluate themechanical properties of the reinforced castings.Research includes fracture toughness and ballisticevaluation to be conducted at LANL.

Keywords: Metalcasting, Squeeze Casting, Aluminum,Reinforcement

133. FERRITE MEASUREMENTS IN DUPLEXSTAINLESS STEEL CASTINGS$120,000DOE Contact: Ehr Ping HuangFu (202) 586-1493University of Tennessee Contact: Carl Lundin

(865) 974-5310

Duplex stainless steel castings are receiving greaterattention since the use of wrought duplex components ison the increase. The duplex stainless steels are nowoften considered for severe service because of theirunique properties with regard to corrosion resistance(especially pitting resistance), strength and toughness.Unfortunately, a standardized method does not currentlyexist for calibrating instruments for the direct assessmentor measurement of the ferrite-austenite phaserelationships. The objective of this project is to developcalibration standards that will be applicable to duplexstainless steel castings and which will cover the fullspectrum of the traditional duplexes and the newly-introduced super duplex , which contains special alloyadditions for enhanced properties.

Keywords: Metalcasting, Calibration, Duplex StainlessSteel

134. TECHNOLOGY FOR THE PRODUCTION OFCLEAN, THIN WALL, MACHINABLE GRAY ANDDUCTILE IRON CASTINGS$107,000DOE Contact: Ehr Ping HuangFu (202) 586-1493University of Alabama - Birmingham Contact:


The primary focus of this project is to determine how themachinability of gray and ductile iron castings can beimproved to support the development of thin walled grayand ductile iron castings for use in the groundtransportation industry. Excessive microcarbides havebeen found in prior research to be a dominant factordegrading machinability of iron castings. One of the majoremphases is to determine how the occurrence ofmicrocarbides can be controlled by normal foundryprocessing changes.

Keywords: Metalcasting, Gray Iron, Cast Iron,Inclusions, Machinability

135. IMPROVEMENTS IN SAND MOLD/CORETECHNOLOGY: EFFECTS ON CASTING FINISH$106,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Ohio State University Contact: John Lannutti

(614) 292-4903

The overall objective of the project is to develop afundamental understanding of how sand structurecontrols the final casting finish of metal castings madeusing sand molds and cores. In this project, Ohio StateUniversity will undertake a study of the effects ofmold/core uniformity by combining an advanced non-destructive X-ray analysis and an optical profiler. Theproject will generate a fundamental understanding of howmetal surfaces form in contact with sand molds/cores.The effort will focus on chemically bonded sands.

Keywords: Metalcasting, Sand Mold, Casting Finish

136. HEAT CHECKING AND WASHOUT OFSUPERALLOYS FOR DIE INSERTS$100,000DOE Contact: Ehr Ping HuangFu (202) 586-1493Case Western Reserve University Contact:

Jack Wallace (216) 368-4222

The project has three main objectives: 1) develop andevaluate nickel and cobalt-base superalloys for use asinserts in die casting of aluminum alloys, 2) design andrun a full size "erosion test" for evaluating washout in dieinsert materials, and 3) study the mechanisms of thermalfatigue crack nucleation and propagation in superalloysand compare these to thermal fatigue cracking of steels.

Keywords: Metalcasting, Die Casting, Heat Checking,Inserts

INDUSTRIAL MATERIALS FOR THE FUTURE

New or improved materials can save significant energyand improve productivity by enabling systems to operateat higher temperatures, last longer, and reduce capitalcosts. The Industrial Materials for the Future (IMF)program is a crosscutting program with emphasis onmeeting the industrial needs of the Industries of theFuture effort and of crosscutting industries including thecarbon products, forging, heat treating, process heating,and welding industries. Efforts in FY 2002 were focusedon development of the new IMF program plan and issuingproposals related to the industry, academia, and nationallaboratory sectors. The DOE program managers are SaraDillich (202) 586-7925 and Mike Soboroff (202) 586-4936.


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MATERIALS PREPARATION, SYNTHESIS,DEPOSITION, GROWTH, OR FORMING

137. ADVANCED MATERIALS/PROCESSES $1,090,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goals of this project are to develop new andimproved materials and materials processing methods.Metallic, intermetallic alloys, refractories and ceramicspossess unique properties and have the potential to bedeveloped as new materials for energy relatedapplications. In FY 2001, R&D also utilized the new300,000 W high intensity infrared heating and processingsystem. Research conducted related to surfacemodification of ceramics, refractory and alloy systems,materials properties, thermodynamics, and hightemperature filtration materials.

Keywords: Intermetallic, Metalcasting, Glass, Alloys,Welding, Corrosion Resistance, Infra RedHeating, Coatings, Refractories, WC,Thermodynamics, Materials Properties,Thermal Spray, Ceramics, MaterialsProcessing

138. CONDUCTING POLYMERS: SYNTHESIS ANDINDUSTRIAL APPLICATIONS$150,000DOE Contact: Mike Soboroff (202) 586-4936Los Alamos National Laboratory Contact:

S. Gottesfeld (505) 667-0853

In FY 2001, the use of conducting polymers forelectrochemical reactors (ECRs) based on polymericelectrolytes was addressed. The objective of this effort isto develop and test electrochemical reactors for the chlor-alkali industry, based on polymer membrane/electrodeassemblies and on oxygen or air electrodes. In FY 2001,development of the oxygen polarized chlor-alkali cellswas continued.

Keywords: Electrically Conducting Polymers, GasSeparation, Electrochemical Reactors,Cathodes

139. DEVELOPMENT OF ADVANCEDMETALLIC/INTERMETALLIC ALLOYS$670,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contacts: P. J. Maziasz (865) 574-5082,

M. L. Santella (865) 574-4805, V. K. Sikka (865)574-5112 and C. T. Liu (865) 574-4459

The objectives of this project are to develop advancedintermetallic alloys including FeAl and Ni3Si. The FeAleffort is focused on alloys with improved weldability and

mechanical and corrosion properties for use in structuralapplications; and the development of weldable FeAlalloys for use in weld-overlay cladding applications. TheNi3Si effort is focusing on alloy composition, and welding.Developments made in FY 2001 included;1) improvement of the ductility and joining of nickelsilicide, 2) development of autogenous and dissimilarmetal welding of iron aluminide, and 3) corrosion studiesin carburizing environments.

Keywords: Iron Aluminides, Nickel Aluminides,Coatings, Claddings, ThermophysicalProperties, Casting, ThermomechanicalProperties, Chemical Industry, SteelIndustry, Welding, Alloys, Intermetallic,Joining

140. HIGH TEMPERATURE FACILITATEDMEMBRANES$350,000DOE Contact: Mike Soboroff (202) 586-4936Los Alamos National Laboratory: D. J. Devlin

(505) 667-9914

The project focuses on the development of membranesand a test system for their evaluation. The purpose of theproject is to develop and evaluate a new high-temperature membrane for the separation of carbondioxide from hydrogen. The approach involves the use ofmolten carbonate type materials with reversibility,measurement of transport properties throughmembranes, and the evaluation of decomposition tooxide on the downstream side. In FY2001, progress wasmade in fabricating membranes of lithium carbonate onmetallic substrates.

Keywords: Membranes, Liquid Vapor Separations,Oxygen, Carbon Dioxide, Natural Gas,Corrosion

141. INTERMETALLIC ALLOY DEVELOPMENT ANDTECHNOLOGY TRANSFER OF INTERMETALLICALLOYS$2,458,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contacts: M. L. Santella (865) 574-4805

and V. K. Sikka (865) 574-5112University of Tennessee Contact: G. M. Pharr

(865) 974-8202

The objective of this project is to develop and apply theexcellent oxidation and carburization resistance andhigher strength of intermetallic alloys including nickelaluminides to Industries of the Future relatedmanufacturing applications. Progress in bringingtechnologies to development and commercialization inFY 2000 included: 1) processing of radiant tubes androlls for testing and evaluation, 2) the evaluation of long


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term stability tests of nickel aluminide, and 3) joiningtechnology for the iron aluminide system.

Keywords: Nickel Aluminides, Processing, Steel,Metalcasting, Heat Treating, Welding,Chemical Properties, Intermetallic, Alloys,Joining

142. PLASMA PROCESSING - ADVANCEDMATERIALS FOR CORROSION AND EROSIONRESISTANCE$300,000DOE Contact: Mike Soboroff (202) 586-4936Los Alamos National Laboratory: M. Trkula

(505) 667-0591

The project focuses on developing coating technologiesto obtain erosion, and corrosion resistant, thermo-dynamically stable, and adherent coatings on diematerials used to cast aluminum and other metals. Lowtemperature organo-metallic chemical vapor depositioncombined with immersion ion processing is beingdeveloped as the coating technology. In FY 2001, variouscoatings were produced on substrates and evaluated.

Keywords: Plasma, Processing, Corrosion, Erosion,Coatings, Materials, Metals

143. DEVELOPMENT OF ULTRANANOCRYSTALLINEDIAMOND (UNCD) COATINGS FOR SiCMULTIPURPOSE MECHANICAL PUMP$250,000DOE Contact: Mike Soboroff (202) 586-4936

The objectives of this project are to (a) understand thefundamental processes involved in the growth of UNCDcoatings (b) develop a technological base for UNCDapplications, and (c) demonstrate the applicability ofUNCD coatings in industrial applications, such asmultipurpose mechanical pump seals.

Until recently, control of diamond microstructure waslimited to affecting the crystal orientation (texturing) butnot, in a significant way, the crystallite size. A majoradvance was achieved at Argonne National Laboratoryrecently, when it was discovered that diamond filmmicrostructure could be controlled so that crystallite sizespans the range from the micron to the nanometer size, afactor of a million in volume. The commercialization ofUNCD-based seals will require development ofmicrowave plasma chemical vapor deposition tools forgrowing high quality, cost efficient UNCD coatings.

Keywords: Coatings, Chemical Vapor Deposition,Ultrananocrystalline Diamond

144. EXPLORING ULTRAHIGH MAGNETIC FIELDPROCESSING OF MATERIALS FORDEVELOPING CUSTOMIZEDMICROSTRUCTURES AND ENHANCEDPERFORMANCE$200,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

Demonstrate and document the influence of ultrahighmagnetic field processing on the phase equilibria inferrous alloys. The principal objective is to evaluatemagnetic processing as a viable and robust newtechnology for altering phase equilibria and phasetransformation kinetics in a ferrous alloy with the goal ofdeveloping novel microstructures and propertiesunattainable through conventional thermomechanicalprocessing approaches. The secondary objective is todevelop the predictive capability to establish the influenceof an applied magnetic field on ferrous alloys with theability to extend this capability to more generalferromagnetic, paramagnetic, and diamagnetic materialsSince essentially all materials have some form offerromagnetism or paramagnetism, magnetic fieldprocessing is directly applicable to a multitude ofmaterials for dramatically influencing phase stability andphase transformation kinetics through appropriateselection of magnetic field strength promises to provide avery robust mechanism to develop and tailormicrostructures for a broad spectrum of materialsapplications. Ferrous alloys will be studied initially sincethis alloy family exhibits ferromagnetism over part of itstemperature range of stability and therefore woulddemonstrate the maximum impact of this novelprocessing mechanism. Thermodynamic calculationcapability will be developed to enable parametric studiesto be performed to predict the magnitude of the influenceof magnetic processing variables on the phase stability inparamagnetic and diamagnetic materials of relevance tothe Industries of the Future.

Keywords: Ferromagnetism, Paramagnetism,Microstructures, Ferrous Alloys, MagneticField Processing

145. INVERSE PROCESS ANALYSIS FOR THEACQUISITION OF ACCURATETHERMOPHYSICAL DATA$250,000DOE Contact: Mike Soboroff (202) 586-4936

The goal of this project is to improve the acquisition ofdata on thermophysical properties (including solid fractionand density during solidification) by developing realisticthermal models and concurrently using inverse-typecomputational analyses of the measurement process.New computational methodologies and measurementprocedures will be developed to obtain accurate data on


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thermophysical properties. Methodologies include high-heat-flux DSC and dual-push-rod dilatometer analyses.By performing a computational analysis of themeasurement process, the time lag and thermalresistances can be estimated and their effect can betaken into account in determining more accurate data onthermophysical properties. The tasks include Developanalytical models for DSC, Develop analytical models fordilatometry, Conduct DSC and dilatometrymeasurements, Experimentally validate the proposedmethodologies, and Evaluate and summarizeexperimental and computational procedures.

Keywords: Dilatometry, Thermophysical Properties,DSC

146. DEVELOPMENT OF STRONGER AND MORERELIABLE CAST AUSTENITIC STAINLESSSTEELS$300,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goal of this project is to increase the high-temperature creep strength by 50% and the upper-usetemperature by 30 to 60/C for HP-modified and 100 to200/C for modified HK cast austenitic stainless steels.The R&D will focus on the use of alloy design methodsdeveloped at the Oak Ridge National Laboratory (ORNL),based on precise micro characterization and identificationof critical microstructure/ properties relationships, and oncombining them with the modern computational science-based tools that enable the prediction of phases, phasefractions, and phase compositions based on alloycompositions. The combined approach of microcharacterization of phases and computational phaseprediction will permit rapid improvement of a current classof alloy compositions with the long-term benefit ofcustomizing alloys within grades for specific applications.

Keywords: Steel, Microstructure Properties, Alloys

147. ULTRASONIC PROCESSING OF MATERIALS$150,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goals of the project are to evaluate the coreprinciples, establish a quantitative basis for the ultrasonicprocessing of materials, and to demonstrate keyapplications in the areas of 1) grain refinement of alloysduring solidification, and 2) degassing of alloy melts. Thisstudy will focus on two classes of materials, aluminumalloys and specialty steels, and will demonstrate theapplication of ultrasonic processing during ingot (andcontinuous) casting, foundry shape casting, and vacuumarc remelting. This investigation proposes to study theeffects of acoustic energy of varying phonon energy and

frequency introduced during the melting and solidificationprocess. Acoustic frequencies from dc to 100 MHz, andcontinuous acoustic input power of up to 100 watts will beused. Variables will be input acoustic power, inputacoustic frequency, and cooling rate.

Keywords: Ultrasonic Processing, Alloys, Metals, GrainRefinement, Degassing, Casting, Steel

148. HIGH ENERGY DENSITY COATING OF HIGHTEMPERATURE ADVANCED MATERIALS FORENERGY EFFICIENT PERFORMANCE$150,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goal of the project is to develop a reliable, efficient,and economic method of coating ceramic on metal byusing a high-energy-density technique. The process andcoating-substrate material systems will be optimized tosuit specific industrial applications. The goal also includescharacterization of processed coating-substrate materialsystems for wear and corrosion properties under variousconditions. The correlation between coating propertiesand process parameters will be established. The majorobjectives of the research activity are 1) to understandthe chemical, physical, and microstructural transforma-tions taking place in the selected representative systemsduring LPIASM treatment (this knowledge about varioustransformations is necessary to subsequently develophighly efficient and cost-effective customized applicationsfor surface protection/modification) and 2) to develop atechnique for modifying the surfaces of variousgeometries and materials for enhanced wear andcorrosion properties in real components.

Keywords: Ceramic, Advanced Materials, Coatings,Wear, Corrosion

149. NOVEL CARBON FILMS FOR NEXTGENERATION ROTATING EQUIPMENTAPPLICATIONS$225,676DOE Contact: Mike Soboroff (202) 586-4936

This project aims to combine the unique qualities of twonovel carbon technologies to achieve extended wear lifeand higher energy savings in rotating-equipmentapplications, including mechanical seals, sliding bearings,and shafts. Materials to be explored in this project are asuper low-friction carbon film [Near Frictionless Carbon(NFC)] and a carbon conversion film with structure andproperties ranging from graphite to diamond [CarbideDerived Carbon (CDC)]. The focus of the R&D is thedevelopment of adherent, low-friction, wear-resistantcoatings for SiC and other metal carbide ceramics forrotating seal applications. Activities will include treatingSiC components to produce CDC surface layers,


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characterizing the coatings and substrates, andevaluating of coated components tested in the laboratoryand in industry. NFC coatings will be applied to bothuntreated and CDC-treated components.

Keywords: Carbon Materials, Rotating Equipment,Coatings, Ceramics, SiC

150. ADVANCED COMPOSITE COATINGS$300,000DOE Contact: Mike Soboroff (202) 586-4936

The goal of the project is to develop low-cost, high-temperature corrosion-resistant coatings with superiormechanical properties for industrial applications. Twomethods will be used to fabricate high-temperaturecorrosion resistant ceramic coatings: pyrolysis ofpreceramic precursors and in situ displacementreactions. Both routes require a thorough understandingof the materials development during coating fabricationand the properties of the material that control the coatingbehavior. In addition to pursuing these two coatingtechniques, composite coatings will also be developed asa means to further improve coating performance.Composite coatings will consist of preceramic polymer-derived or in situ displacement reaction materialcombined with additional constituents that can improvecorrosion resistance, mechanical properties, and thermalproperties. Tasks include development of corrosionresistant compositions, coating adhesion, andcharacterization and optimization for serviceenvironments.

Keywords: Coatings, Mechanical Properties, Ceramics,Pyrolysis, Corrosion Resistance, ThermalProperties

151. HIGH-DENSITY INFRARED SURFACETREATMENTS OF REFRACTORIES$200,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goal of the project is to make a major advancementin improving the behavior of refractory materials used inindustrial processes. Refractories play an integral part inthe operations of numerous industries of the future, andadvancements can have a significant and large impact onthe viability of those industries. These improvements willbe realized through surface modifications with HDI. Theproject will be performed as a series of tasks. Theobjectives of the three tasks are 1) demonstrate theability to reduce open surface porosity on commerciallyavailable refractories and evaluate the corrosion behavior2) fabricate corrosion-resistant surface layers onrefractories by either diffusion coating or selectivesintering of secondary layers, and 3) produce refractories

having high-emissivity surface coatings (in addition to lowporosity and high corrosion resistance).

Keywords: Infrared, Refractories, HDI, Porosity,Corrosion Resistance, Coatings, Sintering

152. DEVELOPMENT OF A NEW CLASS OFFERRITIC STEELS FOR INDUSTRIAL PROCESSAPPLICATIONS$500,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

Development of a new class of Fe-3Cr-W(V) steels with1) 50% higher tensile strength at temperatures up to650/C than current alloys 2) potential for not requiringany PWHT 3) equipment weight reduction of 25 percent,and 4) impact properties of approximately 100 ft-lb uppershelf energy and -10/F (-20/C) for DBTT withouttempering treatment. The project objectives will be metthrough a range of concepts: 1) alloy compositionoptimization through the use of thermodynamic/ kineticmodeling 2) development of time-temperature-transformation curves for defining selective heat-treatment conditions 3) melting and processing laboratoryand large-scale heats 4) welding and fabrication processdevelopment 5) physical and mechanical properties ofbase and weldments, and 6) testing of prototypecomponents and preparation of data packages for ASTMand ASME Code approvals.

Keywords: Ferritic Steels, High Tensile Strength,Alloys, Thermodynamic Modeling, Welding,Mechanical Properties

153. CROSSCUTTING INDUSTRIAL APPLICATIONSOF A NEW CLASS OF ULTRAHARD BORIDES$245,000DOE Contact: Mike Soboroff (202) 586-4936Ames Laboratory, Iowa State University Contact:

Bruce Cook (515) 294-9673

The goal of this project is to develop a new class ofultrahard materials, based on the complex borideAIMgB14, into high-performance, cost-effective solutionsfor a wide range of key industrial focus areas, includingmetalcasting, forest products, mining, and agriculture.Some of the challenges to be addressed in thedevelopment of the new AIMgB14 technology will be tounderstand and control the formation of deleterious oxidephases during processing, to identify appropriate large-scale mechanical alloying techniques best suited forprocessing nanometric boride, and to characterize


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properties such as its low ductility and impact resistance(fracture toughness).

Keywords: Borides, Metalcasting, Forest Products,Mining, Agriculture, Alloys, Ductility,Fracture Toughness

154. DEVELOPMENT OF ADVANCED WEAR ANDCORROSION RESISTANT SYSTEMS THROUGHLASER SURFACE ALLOYING AND MATERIALSSIMULATION$170,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

Development of processing and material simulationtechniques for identifying and creating reproducibleadvanced coatings through the LSA process. 1) Extendthe laser process, computational thermodynamics andkinetic models to describe the microstructure evolutionduring LSA processing for well-characterized processconditions. 2) Evaluate the predictions with experimentalmicroscopy and analysis. 3) Use the theoretical modelsand experimental measurements to develop newadvanced composite-coating systems with collaboratingindustrial members.

Keywords: Coatings, Alloys, Laser Surface Alloying,Thermodynamic Models, AdvancedComposites, Microscopy, Corrosion

155. DEVELOPMENT AND DEMONSTRATION OFADVANCED TOOLING ALLOYS FOR MOLDSAND DIES$180,000DOE Contact: Mike Soboroff (202) 586-4936Idaho National Engineering and Environmental

Laboratory Contact: Kevin McHugh (208) 526-9662

The goal of the project is to research, develop, anddemonstrate a new class of tooling alloys that improveproductivity, increase die life, and at the same time,reduce the energy consumed during the production ofdies used in glass component manufacture, forging, diecasting, and stamping. The objectives of this effortinclude increasing die life by a minimum of 20 percentand reducing energy consumption associated with themanufacture and heat treatment of dies by a minimum of25 percent.

Keywords: Alloys, Molds, Glass, Forging, Die Casting,Heat Treating

156. NOVEL SUPERHARD MATERIALS ANDNANOSTRUCTURED DIAMOND COMPOSITES$358,000DOE Contact: Mike Soboroff (202) 586-4936Los Alamos National Laboratory Contact:

Zhao, Yusheng (505) 667-3886

The goal of this R&D project is to synthesize novelsuperhard B-C-N materials and to manufacturenanostructured diamond/SiC composites. The projectcovers a broad research scope of high-pressure, high-temperature synthesis, property characterization, andindustrial implementation. The success of this project canhave significant technological impacts for future industrialapplications in many fields. The successful synthesis ofthe superhard B-C-N materials and nanostructureddiamond/SiC composites will require (a) advanced high-pressure techniques with the use of a unique Pt capsuleto confine the volatile phases (b) the effective use ofsuitable solvents and catalysts to promote synthesisreaction and crystallization, and (c) the appropriateselection of the composition and particular preparation ofstarting materials.

Keywords: Diamond Composites, Superhard Materials,Nanostructure, Solvents, Catalysts,Crystallization, High Pressure Techniques,SiC

157. ADVANCED NANOPOROUS COMPOSITEMATERIALS FOR INDUSTRIAL HEATINGAPPLICATIONS$300,000DOE Contact: Mike Soboroff (202) 586-4936Lawrence Berkeley National Laboratory Contact:

Arlon Hunt (510) 486-5370

The goal of the project is to develop new insulatingmesoporous composite materials for process-heatingapplications. The major objective of this project involvesdeveloping aerogel composite materials that retain theadvantageous properties of standard aerogels whileincreasing their mechanical and chemical compatibilityproperties to the levels necessary to meet the needs ofvarious IOF industries. The approach for creatingcomposite materials with tailored thermal and mechanicalproperties is based on sol-gel technology, which will beused to create refractory multicomponents from a porousmonolithic gel, followed by supercritical solventextraction. Post-processing techniques, includingchemical vapor infiltration and advanced packagingprocesses, will also be developed. The packagingprocesses include the incorporation of fibrous orparticulate materials as mechanical enhancements andinfrared opacifants, exterior dense oxide coatings, andshaping/forming processes. Aerogels similar incomposition to the oxide ceramics used today forrefractories will be prepared, and their thermal and


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mechanical properties will be evaluated. Advancedcomposite structures will be prepared and similarlyanalyzed.

Keywords: Nanoporous, Advanced CompositeMaterials, Mesoporous, Process Heating,Aerogels, Sol-Gel, Refractories, MonolithicGel, Chemical Vapor Infiltration, FibrousMaterials, Infrared Opacifants, Coatings,Ceramics, Mechanical Properties

158. HIGH DENSITY INFRARED (HDI) TRANSIENTFUSED COATINGS FOR IMPROVED WEAR ANDCORROSION RESISTANCE$300,000DOE Contact: Mike Soboroff (202) 586-4936

The project’s aims are 1) to develop, evaluate, andunderstand how high density infrared heating technologycan improve infiltrated carbide wear coating systems and2) to better understand the densification and metallurgicalbonding within HDI/TLC coatings. A basic understandingof the dilutive mixing of coating with base material is keyto successful technology development. In the proposedwork, both applied and fundamental investigations will beconducted. The applied work would develop practicalHDI/TLC systems that would be capable of fusing carbidecoatings for industrial applications.Engineering development would focus on developing theprocess and equipment technology necessary toimplement industrial HDI systems that can fuse coatingson such parts. The fundamental research would be aimedat understanding the effect of HDI processing on thecoating materials and the subsequent coating properties.This work would develop the necessary materials andprocess knowledge to enable the control of the HDIprocess and the proper specification of coating precursor.

Keywords: High Density Infrared Heating Technology,Coatings, Bonding, Corrosion Resistance

MATERIALS PROPERTIES, BEHAVIOR,CHARACTERIZATION, OR TESTING

159. MATERIALS DEVELOPMENT FOR THE FORESTPRODUCTS INDUSTRY$400,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: Peter Angelini (865) 574-4565

The purpose of this project is to determine the cause offailure of composite tubes used in Kraft Black Liquorrecovery boilers during pulp and paper making, and todevelop new materials to eliminate failures. The projectconsists of three efforts: 1) to obtain operating data andfailure analyses, 2) determination of residual stresses innew and used composite tubes and microstructuralcharacteristics of tubes, and 3) development of new

materials and/or fabrication methods for improvements inboiler efficiency, service life, and safety. In FY 2001, themain effort was related to the materials behavior of walltubes specifically near airports of Kraft recovery boilers.Various companies continued installation of retrofittedparts of floors with the new materials. Temperaturemeasurements of tubes at air ports were continued andresults highlighted the influence and significance ofthermal cycling on the corrosion/cracking behavior oftubes at those locations. Participants include Oak RidgeNational Laboratory (ORNL), Institute of Paper Scienceand Technology (IPST), the Pulp and Paper ResearchInstitute of Canada (PAPRICAN), 18 pulp and papercompanies, and six boiler and materials suppliers.

Keywords: Corrosion, Recovery Boilers, CompositeTubes, Pulp and Paper, Alloys, Stresses,Neutron Residual Stress, Measurements,Modeling, Mechanical Properties

160. METALS PROCESSING LABORATORY USERS(MPLUS) FACILITY $1,000,000DOE Contact: Mike Soboroff (202) 586-4936Oak Ridge National Laboratory Contact:

P. Angelini (865) 574-4565

The Metals Processing Laboratory User (MPLUS) Facilityis an officially designated DOE User Facility. It’s primaryfocus is related to the Office of Industrial Technologies(OIT) efforts including the "Industries of the Future",national, and cross cutting programs. The purpose ofMPLUS is to assist U. S. industry and academia inimproving energy efficiency and enhancing U. S.competitiveness. MPLUS includes the following usercenters: Metals Processing, Metals Joining, MetalsCharacterization, and Metals Process Modeling. As of theend of FY 2001, 0ver 160 proposals were received withover 60 MPLUS projects having been completed.Projects crosscut all of the industries in the Industries ofthe Future effort and other supporting industries includingforging, heat treating, welding.

Keywords: Industry, User Center, Metals, Materials,Processing, Joining, Properties,Characterization, Modeling, Process,Welding

161. DEVELOPMENT OF COMBINATORIALMETHODS FOR ALLOY DESIGN ANDOPTIMIZATION$200,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

This project aims to develop a comprehensivemethodology for designing and optimizing metallic alloysby combinatorial principles. Combinatorial methods


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promise to significantly reduce the time, energy, andexpense needed for alloy design, largely becauseconventional techniques for preparing alloys areunavoidably restrictive in the range of alloy compositionsthat can be examined. The basic concept is to develop atechnique that can be used to fabricate an alloy specimenwith a continuous distribution of binary and ternary alloycompositions across its surface – an “alloy library” – andthen use spatially resolved probing techniques tocharacterize the structure, composition, and relevantproperties of the library. As proof of principle, themethodology will be applied to the Fe-Ni-Cr ternary alloysystem that constitutes the commercially important H-series and C-series heat- and corrosion-resistant castingalloys. Combinatorial methods will also be developed toassess the resistance of these materials to carburizationand aqueous corrosion, properties important in theirapplication.

Keywords: Combinatorial, Alloys, Casting,Carburization, Corrosion

162. STOCHASTIC MULTI-OBJECTIVEOPTIMIZATION OF HEAT AND CORROSIONRESISTANT ALLOY PROPERTIES$186,617DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The project will create a computational modeling tool tocustomize H-series alloys for specified applications andrequired properties. The tool will reduce or minimize theneed for the addition of expensive alloying elements(including Cr, Ni, Co, Nb, Ti, V) while obtaining theoptimum properties needed to design the components.This project focuses on the industry-wide need forimproving materials-property performance for theapplications that they are currently used for and toincrease alloy upper-use temperature, thus leading toimproved process efficiencies, including chemical andheat-treating processes carried out at highertemperatures than are currently used. The project takesthe new approach of using stochastic optimizationalgorithms for optimizing H-Series steel compositionswith a minimum number of experimental measurementsof the composition/properties of candidate alloys. Theapproach has the potential of identifying newcompositions that cannot be identified without carryingout hundreds of experiments. Furthermore, the approachhas the potential for creating and designing alloys forspecific applications, thereby maximizing their utilizationat reduced cost.

Keywords: Computational Modeling, Alloys, StochasticOptimization Algorithms, Heat Treating,Corrosion

163. FRACTURE TOUGHNESS AND STRENGTH IN ANEW CLASS OF BAINITIC CHROMIUMTUNGSTEN STEELS$124,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The project focuses on high fracture toughness andstrength for a new class of Fe-3Cr-W (V) steels throughunderstanding of their toughening and strengtheningmechanisms. This class of steels has 1) 50 percenthigher tensile strength at temperatures up to 550 to600/C than current alloys 2) high fracture resistance, and3) potential for not requiring any postweld heat treatment(PWHT). However, this new class of Fe-3Cr-W(V) steelsis not of sufficient maturity due to lack of understanding1) microstructure-controlled strengthening andtoughening, which can lead to further development of thesteels, and 2) the fracture toughness relationship withmicrostructure in weldments before and after PWHT.Experiments will be performed on the new class of Fe-3Cr-W(V) steels. Specimens will be prepared at ORNL byvacuum arc melting, solidification, hot rolling,austenitizing at 1050/C, and normalization in argon.Some of specimens will be tempered at 700/C. Weldingwill be also performed on the new class of Fe-3Cr-W(V)steels. The University of Pittsburgh will carry out themicrostructure characterization by the use oftransmission electron microscopy (TEM) and energy-dispersive spectroscopy (EDS), measure the tensileproperties and characterize the microstructure ofprestrained specimens by TEM, and determine thefracture toughness by performing JIC tests andsubsequent atomic force microscope (AFM) analysis ofareas near the crack tip.

Keywords: Steel, Fracture Toughness, Welding, HeatTreating, Microstructure Characterization,Alloys

164. CHARACTERIZATION AND STRUCTURALMODELING OF MAGNESIA-ALUMINA SPINELREFRACTORIES$300,565DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goal of the project is to characterize key properties ofrefractory materials to improve thermal efficiencies andmanagement in industrial combustion environments.Physical and mechanical properties (including creep,thermal conductivity, microstructure, and phasecomposition) will be evaluated for two spinel glass tankcrown refractories. This information will then be used to


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model and validate the long-term reliability of glass tankcrowns.

Keywords: Refractories, Thermal Efficiencies,Mechanical Properties, Glass, Modeling

165. THERMOCHEMICAL MODELS HIGH-TEMPERATURE MATERIALS PROCESSINGAND CORROSION$200,000DOE Contact: Mike Soboroff (202) 586-4936Sandia National Laboratories Contact:

Mark Allendorf (925) 294-2895

The goal of the project is to greatly improve theavailability, accuracy, and accessibility of thermochemicalproperty data required to understand, simulate, andoptimize industrial processes involving glass andrefractory materials at high temperatures. The objective isto employ advanced computational techniques to developa coherent database of thermochemical values and setsof models for gas and condensed-phase systems ofimportance to the processing of glass and to theindustrial use of refractories. The product will be a web-based database/model information site that will providethe necessary input for commercial application.

Keywords: Glass, Refractory, Thermochemical, HighTemperature, Advanced ComputationalTechniques, Corrosion, MaterialsProcessing

166. VIRTUAL WELD-JOINT DESIGN INTEGRATINGADVANCED MATERIALS AND PROCESSINGTECHNOLOGIES$250,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The primary goal of this project is to use an integratedmodeling approach to increase weld joint serviceperformance by 10 times and to reduce energy use by 25percent through performance and productivityimprovements. This integrated model will address basematerial selection, weld consumable design, weldingprocess parameters optimization, weld residual stressmanagement, and fatigue resistance improvement. Theproject will integrate existing modeling tools with newenhancements to develop a systematic microstructure-level modeling approach for the design of a high-performance weld joint. The systematic modelingapproach will lead to an optimized weld joint design byconsidering the combined effects of weld bead geometry,microstructure, material property, residual stress, and thefinal fatigue strength. The computer–aided virtual weldjoint design will also enable improvement of themanufacturing quality, resulting in increased

manufacturing productivity and reduced energyconsumption for welding and reduced welding emissions.

Keywords: Welding, Advanced Materials, Modeling

167. STRESS-ASSISTED CORROSION (SAC) INBOILER TUBES$276,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The goal of this project is to clarify the mechanisms ofSAC of boiler tubes for determining key parameters in itsmitigation and control. The centerpiece of this R&D is thedevelopment of a laboratory test that 1) simulates SAC inindustrial boilers and 2) permits the control of keyconditions to establish the parameters that have thegreatest effects on SAC initiation and propagation. TheR&D partners and industry contributors will useinformation gathered across multiple industries, make insitu measurements of strain and water chemistry inoperating boilers, and perform laboratory simulations ofSAC. Through these activities, significant environmental,operational, and material characteristics will be identifiedto select parameters for each that reduce the frequencyand severity of SAC. In addition, risk factors for SAC willbe identified to determine inspection intervals andpriorities for control. It is anticipated that the results willyield increased operating efficiencies represented bydecreased downtime (greater intervals betweeninspection and maintenance cycles) with associatedenergy and cost savings.

Keywords: Stress Assisted Corrosion, Tubes, IndustrialBoilers, Strain and Water Chemistry

MATERIALS STRUCTURE AND COMPOSITION

168. DEVELOPMENT OF COST-EFFECTIVE LOWPERMEABILITY CERAMIC AND REFRACTORYCOMPONENTS FOR ALUMINUM MELTING ANDCASTING$300,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: P. Angelini (865) 574-4459

The focus of this project is to develop and validate newclasses of cost effective low-permeability ceramic andrefractory components for handling molten aluminum inboth smelting and casting environments. The primarygoal is to develop materials and methods for sealingsurface porosity in thermal shock- resistant ceramicrefractories, which will also include the evaluation ofmonolithics used in the low-pressure casting ofaluminum. The approach includes understanding thefailure mode of refractory tubes in molten aluminum,characterizing of the porosity in delivery tubes, evaluatingmonolithic tube materials, developing and optimizing the


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surface modification process to close the porosity, andchoosing a refractory powder blend that minimizes theporosity.

Keywords: Aluminum, Casting, Ceramic, Refractories,Smelting, Monolithics, Tubes, Porosity

DEVICE OR COMPONENT FABRICATION,BEHAVIOR, OR TESTING

169. CONTINUOUS FIBER CERAMIC COMPOSITES(CFCC) - INDUSTRIAL TECHNOLOGIES$750,000DOE Contact: Mike Soboroff (202) 586-4936ORNL Contact: Peter Angelini (865) 574-4565

The Continuous Fiber Ceramic Composites (CFCC)activity operates as a collaborative effort betweenindustry, national laboratories, universities, and thegovernment to develop advanced ceramic compositematerials to a point at which industry will assume full riskof further development. Various industry projects werecompleted. National laboratories, along with universities,continued the development of supporting technologies(e.g., materials design, processing methods, and sensingtechnologies) and conducting performance-basedevaluations.

Keywords: Continuous Fiber Ceramic Composites,Materials Processing

170. SELECTIVE INORGANIC THIN FILMS$250,000DOE Contact: Mike Soboroff (202) 586-4936Sandia National Laboratories Contact:

T. M. Nenoff (505) 844-0340

The purpose of this research is to develop a new class ofinorganic zeolite based membranes for light gasseparation and use this technology to improve onseparation efficiencies currently available with polymermembranes, particularly for light alkanes. The approachis to nucleate and crystallize zeolithic phases from sol-gelderived amorphous coatings, using porous filters and gasmembranes as supports for these films. In FY2001, theR&D continued with advancements made in thefabricability of membrane systems. Keywords: Coatings, Sol-Gel Processing, Membranes,

Separations, Zeolite

171. PHYSICAL AND NUMERICAL ANALYSIS OFEXTRUSION PROCESS FOR PRODUCTION OFBIMETALLIC TUBES$200,000DOE Contact: Mike Soboroff (202) 586-4936

The primary project objective is to understand and controlmetal flow in the coextrusion of bimetal tubes. Twometals will be selected based on their service properties,such as corrosion resistance, elevated-temperatureperformance, strength, ductility, and surface finish.Process parameters such as temperature, ram speed,extrusion ratio, and lubrication on both container andmandrel interfaces with the extruded billet, will beincluded in the final model. One objective of this newlydeveloped numerical model will be to indicate a selectionof extrusion press characteristics (e.g., press capacity,container size) based on the required bimetal tubespecifications.

Keywords: Tubes, Metals, Numerical Modeling, Billet,Extrusion, Corrosion Resistance

172. HIGH PERFORMANCE, OXIDE DISPERSIONSTRENGTHENED TUBES FOR PRODUCTIONOF ETHYLENE$204,956DOE Contact: Mike Soboroff (202) 586-4936

This project seeks to develop higher-temperature, coking-resistant, fabricable tubes for ethylene pyrolysis andsteam methane reforming. Oxide-dispersionstrengthened (ODS) tubes are expected to have highcreep resistance, exhibit substantial fabricability, andshow environmental benefits. Project partners aredeveloping tubes from iron, nickel aluminide, andadvanced metallic alloy materials resistant to the cokingand carburization that plague traditional tubes of cast orwrought high-alloy stainless steel. These novel tubes areexpected to allow an increase of 65/C in tube operatingtemperature during ethylene production and a doubling oftime between decoking cycles at equivalent temperature.The specific objective is to develop a clad INCOLOY™Alloy MA 956/ODS Alloy 803 tubing that exhibits up to afactor of 2 improvement in creep strength and cokingresistance compared with current alloys.

Keywords: Alloys, Furnace Tubes, Ethylene, IndustrialChemicals, Creep Resistance, Coking,Metals, Welding

Solar Energy Technology Program

74

SOLAR ENERGY TECHNOLOGY PROGRAM

FY 2002

SOLAR ENERGY TECHNOLOGY PROGRAM - GRAND TOTAL $36,178,000

NATIONAL PHOTOVOLTAICS PROGRAM $36,178,000


Amorphous Silicon for Solar Cells and Polycrystalline Thin-Film Materials for Solar Cells 14,778,000Film Silicon for Solar Cells 3,500,000Deposition of III-V Semiconductors for High-Efficiency Solar Cells 2,950,000Nanocrystalline Solar Cell Materials 700,000Organic Solar Cell Materials 560,000


Materials and Device Characterization 5,297,000Materials Structure and Composition 6,854,000


Materials Improvement for High-Efficiency Crystalline Silicon Solar Cells 1,139,000Instrumentation and Facilities 400,000


75

SOLAR ENERGY TECHNOLOGY PROGRAM

NATIONAL PHOTOVOLTAICS PROGRAM

The National Photovoltaics Program sponsors research and development with the goal of making terrestrial solarphotovoltaic power a significant and commercially viable part of the national energy mix. From such efforts, privateenterprise can choose options for further development and competitive application in U.S. and foreign electric powermarkets. Approximately 70 percent of the U.S. domestic product is exported to developing countries. The objective ofmaterials research is to overcome the technical barriers that limit the efficiency and cost effectiveness of photovoltaic cells.Conversion efficiency of photovoltaic cells is limited by the spectral response of the semiconductor (dependent on bandstructure), carrier mobility, and device engineering factors. These factors include junction depth, reflection coefficient,parasitic resistances (i.e., series resistance in the metallization and contacts, shunt resistance through the thickness of thecell), and material imperfections that support dark recombination of excess photogenerated carriers. Manufacturing cost isaffected by the expense of semiconductor material growth, the complexity of junction formation and cell fabrication, and thematerial requirements of final module assembly. While most photovoltaics in the U.S. have (historically) been intended forremote stand-alone applications, an increasing number of domestic deployments are intended for a grid-tied (net metering)environment. World-wide photovoltaic module production in CY 2002 is expected to be approximately 540 MW, with about145 MW made in the U.S.


173. AMORPHOUS SILICON FOR SOLAR CELLSAND POLYCRYSTALLINE THIN-FILMMATERIALS FOR SOLAR CELLS$14,778,000DOE Contact: Jeffrey Mazer (202) 586-2455 NREL Contacts: Ken Zweibel (303) 384-6441,

Bolko von Roedern (303) 384-6480 and Harin Ullal (303) 384-6486

Amorphous Silicon: These projects perform research onthe deposition and characterization of amorphous siliconthin films to improve solar cell conversion efficiency andhigh-throughput manufacturability. Efficient conversion ishindered by unintended impurities or undesired structurein the deposited films and by poor uniformity of the filmsover large (4000 cm2) areas. The films are deposited byplasma enhanced chemical vapor deposition (glowdischarge), thermal chemical vapor deposition, andsputtering. The long term goal is to develop technologyfor 15 percent efficient (stabilized) photovoltaic moduleswith cost under $50/m2 and with 30-year lifetime. This willallow system lifetime energy cost under $0.06/kWh, andsubsequent wide competition of amorphous Si-based PVin large-scale distributed power scenarios.

Polycrystalline Thin Films: These projects performapplied research on the deposition of CuIn(Ga,S)Se2(CIGSS) and CdTe thin films for solar cells. Research isfocused on improving conversion efficiency by depositingmore nearly stoichiometric CIGSS and CdTe films, bycontrolling interlayer diffusion and lattice matching inheterojunction structures, and by controlling theuniformity of deposition over large (4000 cm2) areas. Thefilms are deposited by chemical and physical vapordeposition, electrodeposition, and sputtering. The longterm goal is to develop technology for 15 percent efficient

photovoltaic modules with cost under $50/m2 and with 30-year lifetime. This will allow system lifetime energy costunder $0.06/kWh, and subsequent wide competition ofpolycrystalline film-based PV in large-scale distributedpower scenarios.

Keywords: Amorphous Silicon, Amorphous Materials,Polycrystalline Films, Copper IndiumDiselenide, Cadmium Telluride, Coatingsand Films, Chemical Vapor Deposition,Sputtering, Physical Vapor Deposition,Electrodeposition, Semiconductors, SolarCells

174. FILM SILICON FOR SOLAR CELLS$3,500,000DOE Contact: Jeffrey Mazer (202) 586-2455NREL Contact: Ted Ciszek (303) 384-6569,

Ken Zweibel (303) 384-6441 and Harin Ullal(303) 384-6486

These projects perform applied research on the high-throughput deposition of relatively thin crystalline silicon(50-100 microns). Methods include recrystallization ofsilicon powder on inexpensive ceramic substrates, andare amenable to rapid thermal annealing (RTA) andintegrated module manufacturing techniques. The goal isto develop highly cost effective crystalline siliconmodules, with conversion efficiencies in the 12-14percent range.

Keywords: Crystalline Silicon, Film Silicon, SiliconRecrystallization, Rapid Thermal Annealing,Semiconductors, Solar Cells


76

175. DEPOSITION OF III-V SEMICONDUCTORS FORHIGH-EFFICIENCY SOLAR CELLS$2,950,000DOE Contact: Jeffrey Mazer (202) 586-2455NREL Contacts: Sarah Kurtz (303) 384-6475,

Martha Symko-Davies (303) 384-6528 andRobert McConnell (303) 384-6419

These projects perform research on the deposition andconduction properties of III-V semiconductors for superhigh efficiency concentrator solar cells. Research isfocused on precise deposition of layers, elucidation of theproperties of the interfacial regions, and improvedunderstanding of the conduction limiting mechanisms ofthe materials. Conduction limiting mechanisms areparticularly severe in the case of GaInAsN, an otherwisefavorable material for use in a four-junction super highefficiency concentrator cell. The materials are depositedby metal organic chemical vapor deposition, liquid phaseepitaxy, and molecular beam epitaxy. The long-term goalis to develop three- and four-junction III-V-based cellsthat achieve as much as 40 percent efficiency underhigh-ratio concentration.

Keywords: Gallium Arsenide, III-V Materials, High-Efficiency Solar Cells, MOCVD, MBE,Liquid-Phase Epitaxy, Semiconductors,Ternary Semiconductors, QuaternarySemiconductors, Solar Cells, ConcentratorCells

176. NANOCRYSTALLINE SOLAR CELL MATERIALS $700,000DOE Contact: Jeffrey Mazer (202) 586-2455 NREL Contact: Dave Ginley (303) 384-6573 and

Art Nozik (303)-384-6603

These projects focus on the development ofnanocrystalline films (including dye-sensitization ofnanocrystalline films of titanium dioxide), photovoltaicdevices based on nanocrystal composites, nanostructurearrays for multi-junction solar cells, and biomemetic filmsemploying semiconductor nanocrystal composites. Thisfundamental research explores the physical mechanisms,and identifies the limits to efficiency and futurecommercial viability, of these materials.

Keywords: Nanocrystalline Films, Nanostructures, Dye-Sensitized Cells, Nanocrystals, Biomimetics

177. ORGANIC SOLAR CELL MATERIALS $560,000

DOE Contact: Jeffrey Mazer (202) 586-2455 NREL Contact: Robert McConnell (303) 384-6419

These projects explore the physics and chemistry of next-generation organic-based materials which have apotential for efficient and low-cost solar energyconversion. Projects include liquid-crystal based solarcells, polymer hybrid photvoltaics, ordered molecular lightharvesting arrays, and double heterostructure andtandem organic solar cells.

Keywords: Organic Solar Cells, Polymer Solar Cells,Conductive Polymers, Next-GenerationPhotovoltaics


178. MATERIALS AND DEVICE CHARACTERIZATION$5,297,000DOE Contact: Jeffrey Mazer (202) 586-2455 NREL Contact: Pete Sheldon (303) 384-6533

These projects measure and characterize material anddevice properties. Approaches include surface andinterface analysis, electro-optical characterization, andcell performance and material evaluation. These allowstudy of critical material/cell parameters such asimpurities, layer mismatch, and other defects that limitphotovoltaic performance and lifetime. Specifictechniques include deep level transient spectroscopy,electron beam induced current, secondary ion massspectroscopy, scanning electron microscopy andscanning transmission electron microscopy, Augerspectroscopy, Fourier-transform based measurements(e.g., FT-Raman, FTIR, and FT-PL), radio-frequencyphotoconductive decay, ellipsometry, andphotoluminescence.

Keywords: Nondestructive Evaluation, SurfaceAnalysis, Surface Characterization,Semiconductor Microstructure, AnalyticalMicroscopy, Minority Carrier LifetimeMeasurement, Semiconductor Defects,Solar Cell Testing, Module Testing


77

179. MATERIALS STRUCTURE AND COMPOSITION$6,854,000DOE Contact: Jeffrey Mazer (202) 586-2455NREL Contacts: Alex Zunger (303) 384-6672

and Robert McConnell (303) 384-6419

These projects support the fundamental and exploratoryresearch needed for advancement of PV technologies inthe long term—five to ten years—and beyond. Projectsinclude collaboration with Office of Science (SC). Topicsinclude ordering in ternary and quaternary materials, solidstate spectroscopy, solid state theory of photovoltaicsemiconductors, computational material sciences,structure of photoelectrochemical materials such as dye-sensitized solar cell materials, properties of transparentconducting oxides, structure of GaInAsN alloys, impurityprecipitation and dissolution in crystalline silicon, andstructure of hydrogen incorporation in silicon materials.

Keywords: Semiconductor Structure, Solid StateSpectroscopy, Ordering in Semiconductors,Photoelectrochemical Materials,Semiconductor Defects, Crystalline Defects,Semiconductor Impurities, QuaternarySemiconductors, Nanostructured Materials


180. MATERIALS IMPROVEMENT FORHIGH-EFFICIENCY CRYSTALLINE SILICONSOLAR CELLS$1,139,000DOE Contact: Jeffrey Mazer (202) 586-2455NREL Contacts: Ted Ciszek (303) 384-6569,

John Benner (303) 384-6496, and Ed Witt(303) 384-6402

This project performs applied research on crystallinesilicon materials and devices to improve conversionefficiency in a commercially-compatible process. Methodsemploy advanced back-surface fields and silicon nitrideand other bulk passivation treatments to reduce minoritycarrier recombination at cell surfaces and in thebulk. Control of point defects in crystalline silicon isstudied by a variety of techniques, and is thoroughlydiscussed at the NREL-sponsored Silicon Devices andMaterials Conference held in Colorado each August.Much work is done at the DOE Center of Excellence inPhotovoltaics at Georgia Institute of Technology. One ofthe major goals of this project is to develop a rapid-thermal-processing (RTP)-based, screen-printed-contact,photolithography-free protocol that will yield 18 percentefficient 100 cm2 cells on crystalline material. Crystallinesilicon materials for achieving this goal includemulticrystalline silicon made by the Heat Exchange

Method (HEM) and single-crystal silicon made by the Tri-Crystal Czochralski growth method.

Keywords: Crystalline Silicon, Multicrystalline Silicon,High-Efficiency Silicon Cell, Screen PrintingMetallization, Light Trapping, Back-SurfaceField, Rapid Thermal Processing,Crystalline Silicon Defects, Point Defects,Hydrogen Passivation, Silicon NitridePassivation, Tri-Crystals, Heat ExchangeMethod (HEM)

181. INSTRUMENTATION AND FACILITIES$400,000DOE Contact: Jeffrey Mazer (202) 586-2455NREL Contacts: Larry Kazmerski

(303) 384-6600 and Pete Sheldon (303) 384-6533

This project procures modern in-house equipment atNREL, primarily for the measurement andcharacterization of photovoltaic semiconductor materials.This includes equipment for such measurements asellipsometry, Auger analysis, current-voltagecharacteristic, Fourier transform-based spectroscopy,electron microscopy; and also includes equipment suchas MBE, ECR plasma, and sputtering systems for thefabrication of photovoltaic and related materials. Keywords: Semiconductor Measurement Equipment,

Semiconductor Materials Measurement,Semiconductor Characterization, FourierTransform Spectroscopy, Solar Cells,Electron Microscopy, MBE, MOCVD

Weatherization & Intergovernmental Program

78

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM

FY 2002

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM - GRAND TOTAL $4,777,020

FINANCIAL ASSISTANCE PROGRAM $4,777,020

INVENTIONS & INNOVATION (I&I) $2,175,382


A Ceramic Composite for Metal Casting 0Titanium Matrix Composite Tooling Material for Enhanced Manufacture of Aluminum

Die Castings 0A New Energy Saving Method of Manufacturing Ceramic Products from Waste Glass 0Energy-Efficient Production and Utilization of Lightweight Structural Panels 0High Purity Fused Silica Glasses 0Batch Preheat for Glass and Related Furnace Processing Operations 0New Membrane Process for Improved Energy Saving Separations in the Petroleum

Industry 0Lost Foam Casting Quantifier Program 46,058Energy Conservation Waste Reduction in the Processing of Soft (Unfired) Ceramic

Particles via Dynamic Cyclone Classification 93,840Selective Batching for Improved Commercial Glass Melting 40,000New “Direct Pour In-Mold” (DPI) Technology for Producing Ductile and Compacted

Graphite Iron Castings 195,881Clean Production of Coke from Carbonaceous Fines 200,000


Development of Phosphors for Use in High-Efficiency Lighting and Displays 0Energy Saving Lightweight Refractory 0High Intensity Silicon Vertical Multi-Junction Solar Cells 0A Low Energy Alternative to commercial Silica-Based Glass Fibers 0A Viable Inert Cathode for Smelting Primary Aluminum 0Development of Inert Anode for the Primary Aluminum Industry 0Automatic Evaluation of Wood Properties 0Electrochromic Window Film 0High Throughput Vacuum Processing for Innovative Uses of Glass 123,058An Insoluble Titanium-Lead Anode for Sulfate Electrolytes 0Non-Invasive Estimation of Dissolved Alumina Concentration in Hall-Héroult

Reduction Cells 29,200Visible Spectrum Incandescent Selective Emitter 197,876


79

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM (continued)

FY 2002 FINANCIAL ASSISTANCE PROGRAM (continued)

INVENTIONS & INNOVATION (I&I) (continued)


Lightweight and Cost Effective Cast Aluminum Diesel Engine Head withLocalized Reinforcement 195,881

DEVICE OR COMPONENT FABRICATION, BEHAVIOR OR TESTING $278,105

Fabrication and Testing of a Prototype Ceramic Furnace Coil 0Fluted Spiral Membrane Module for Reverse Osmosis of Liquids with Dissolved

and Suspended Solids 0High Energy-Density Double-Layer Capacitor Energy Storage for Photovoltaic Systems 158,166Enabling Tool for Innovative Glass Applications 119,939

INSTRUMENTATION AND FACILITIES $775,483

Development of an Innovative Energy Efficient High Temperature NaturalGas Fired Furnace 0

Improved Process Control of Wood Waste Fired Boilers 0Development of Environmentally Benign Mineral Flotation Collectors 0Thermophotovoltaic Electric Power Generation Using Exhaust Heat in the Glass,

Steel and Metal-casting Industries 0A Hot Eye™ Based Coordinate Measuring Machine for the Forging Industry 69,744Development of a High-Frequency Eddy-Current Separator 72,058Integrated Acoustic Kiln Monitor to Guide Accelerated Drying of Wood 108,058System for Detection and Control of Deposition in Kraft Recovery

Boilers and Monitoring Glass Furnaces 113,058Development and Commercialization of Biopulping 25,058Development of a Lower pH Copper Flotation Reagent System 108,308Monitoring of Refractory Wall Recession Using Radar Techniques 40,000Monitoring of Refractory Wall Recession Using High Temperature

Impact-Echo Instrumentation 39,939Fiber Sizing Sensor/Controller for Optimizing Glass and Polymer Fiber

Manufacturing Processes 199,260

NATIONAL INDUSTRIAL COMPETITIVENESS THROUGH ENERGY, ENVIRONMENTAND ECONOMICS (NICE3) $2,601,638


Pressurized Ozone Membrane Ultrafiltration Methodology for TDS Removal inPaper Mill Process Water for Energy Savings, Production Efficiency,and Environmental Benefits 0

New Efficient and Safe Direct Hydrogen Peroxide Process 390,000Energy-savings Regeneration of Hydrochloric Acid Pickling Liquor 0 Demonstration of Magnetic Elutriation Technology for Clean and Efficient

Processing Iron Ore 0 Commercial Scale Demonstration of Biopulping: a New Energy-Efficient &

Environmentally Benign Technology for Papermaking 468,000


80

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM (continued)

FY 2002

NATIONAL INDUSTRIAL COMPETITIVENESS THROUGH ENERGY, ENVIRONMENTAL AND ECONOMICS (NICE3) (continued)

MATERIALS PREPARATION, SYNTHESIS, DEPOSITION, GROWTH OR FORMING (continued)

Catalytic Cracking Demonstration Plant 0Production-Scale Commercial Demonstration of a Vanadium Carbide

Coating Process for Enhancing Wear Resistance of Metals in Steel and Other Manufacturing Industries 0

The Flex-Microturbine for Pecan Waste: Electricity and Heat in a Nutshell 0Ultra Fine Mineral Recovery Pilot Plant 271,000


Increased Productivity and Reduced Energy Consumption in Metal-casting Using Titanium Matrix Composite Tooling 395,638

Coated Recouperator 0Rapid Heat Treatment of Cast Aluminum Components 0Hot Mill Transfer Bar Edge 0Clean, Efficient Glass Production Using High Luminosity Oxy-gas Burners 343,000Plastic Manufacturing from Recovered Post-Consumer Durable Goods 0

MATERIALS STRUCTURE AND COMPOSITION $0

Lightweight Steel Containers 0


Die Casting Copper Motor Rotors 0Improvement of the Lost Foam Casting Process 0Microsmooth Process on Aluminum Wheels 0Enhanced Application Control of Die Casting Lubricants 0Commercial Demonstration of an Improved Magnesium Thixomolding Process 0Zero Emission Mechanical Seal with Integral Micro Heat Exchanger 234,000Demonstration of a Three-Phase Rotary Separator Turbine 0Demonstration of a Dual Pressure Euler Steam Turbine for Industrial and

Building Applications 0Adjustable Speed Drives for 500 to 1500 H.P. Industrial Applications 0

INSTRUMENTATION AND FACILITIES $500,000

Energy Conserving Tool for Combustion Dependent Industries 0An Automatic High Temperature Steel Inspection and Advice System 500,000Support Inspection: A Method of Inspecting On-Stream Process Piping at

Support Areas 0


81

WEATHERIZATION & INTERGOVERNMENTAL PROGRAM

FINANCIAL ASSISTANCE PROGRAM

The goal of the Financial Assistance Program of the Office of Weatherization and Intergovernmental Program (OWIP) is tosupport technologies within the areas of EERE’s eleven programs: Solar, Wind & Hydropower, Geothermal, Distribution ofEnergy & Electrical Reliability, Biomass, Industrial Technologies, FreedomCAR & Vehicle Technologies, Hydrogen, FuelCells & Infrastructure, and Building Technologies that have a significant energy savings impact and future commercialmarket potential. Financial assistance through a competitive solicitation is offered to: 1) speed the development of newenergy efficient inventions, and 2) leverage industry and other resources to demonstrate, and promote the benefits of energysavings, pollution prevention and cost savings possible through the adoption of clean, energy-efficient industrialtechnologies. OWIP provides grants and assistance to independent inventors and small businesses with promising newideas through its inventions and innovation (I&I) Program. OWIP also provides grants to help fund technologydemonstrations through its National Industrial Competitiveness through Energy, Environment and Economics (NICE3)Program. The DOE contact is Lisa Barnett (202) 586-2212

INVENTIONS & INNOVATION (I&I)DOE Contact: Lisa Barnett (202) 586-2212


182. A CERAMIC COMPOSITE FOR METAL CASTING $0 DOE Contact: Keith Bennett (303) 275-4905 MER Corporation Contact: James Withers

(520) 574-1980

The grant will demonstrate nitride/nitride-carbide ceramiccomposite casting dies. Ceramic composite materialsoffer complete stability to molten metals and are resistantto erosion, oxidation, thermal fatigue, and cracking. Thepotential life span of ceramic composite dies could be tentimes that of coated steel dies.

Keywords: Die Casting, Ceramic Composite, MetalCasting

183. TITANIUM MATRIX COMPOSITE TOOLINGMATERIAL FOR ENHANCED MANUFACTUREOF ALUMINUM DIE CASTINGS $0DOE Contact: Steve Sargent (303) 275-4912 Dynamet Technologies, Inc. Contact:

Susan Abkowitz (781) 272-5967 The grant will produce a metal matrix composite materialcomposed of Ti-6Al-4V and 10-wt percent titaniumcarbide particulate. The titanium metal matrix compositeoffers both dramatically improved (400 percent) durabilityand reduced thermal conductivity (50 percent comparedto steel) that will provide energy savings by reducingpreheating energy consumption by 4-8 percent.

Keywords: Metal Matrix Composite, Titanium,Aluminum, Die Casting

184. A NEW ENERGY SAVING METHOD OFMANUFACTURING CERAMIC PRODUCTS FROMWASTE GLASS$0DOE Contact: Gibson Asuquo (303) 275-4910 Haun Labs Contact: Michael Haun

(707) 538-0584

The grant will develop a new method to lower energycosts of manufacturing ceramic products. The processcalls for the substitution of traditional raw materials withwaste glass. Melting temperatures and associated energyconsumption will decrease by 35-50 percent by sinteringglass powder instead of using traditional ceramicmaterials.

Keywords: Cullet, Ceramic, Sintering Glass Powder

185. ENERGY-EFFICIENT PRODUCTION ANDUTILIZATION OF LIGHTWEIGHT STRUCTURALPANELS$0DOE Contact: Gibson Asuquo (303) 275-4910Genesis Laboratories, Inc. Contact:

Dr. Thomas Owens (630) 879-1112

This grant will demonstrate the feasibility and energysavings of the MWAC method for consolidating andfinishing structural cores used in the production oflightweight sandwich panels.

Keywords: Structural Panels, Building Panels,Sandwich Panels


82

186. HIGH PURITY FUSED SILICA GLASSES$0DOE Contact: Gibson Asuquo (303) 275-4910Rensselaer Polytechnic Institute Contact:

Patricia Gray (518) 273-6659

This grant will prepare high purity silica glasses anddemonstrate their superior characteristics. High puritysilica glasses with superior quality proposed in this workwill be supplied to both electronics industry and to opticalfiber manufacturers. At the present time, no one holds thetechnology rights on the proposed method of high puritysilica glass production.

Keywords: Glass, Optical Fiber, High Purity Silica

187. BATCH PREHEAT FOR GLASS AND RELATEDFURNACE PROCESSING OPERATIONS$0DOE Contact: Steve Sargent (303) 275-4912Energy and Environmental Resources Contact:

William Fleming (765) 647-0076

This grant will prepare various salt eutectics in the lab:chlorides of aluminum, iron (III), sodium, calcium, andmagnesium will be used in these formulations. The saltswill be dissolved in various proportions, and then thewater will be evaporated off. Melting points will then bedetermined in a muffle furnace. The samples which havemelting points in the 200-300°F range will then be testedfurther: in these test, the eutectic salts will be subjectedto high temperature exposure (up to 1800°F) in a smalllab kiln. The samples will be evaluated thermal stabilitybased on weight loss or evolution of gas/vapor, etc. Theeutectic salts will be rated for thermal stability with the top2 or 3 being tested for corrosivity. The salts will then beused on various metal alloys at up to 1800°F. Finally,corrosivity test will be conducted with metal alloyssubjected to sodium sulfate at up to 1800°F.

Keywords: Glass, Glass Furnace, Eutectic Salts, MetalAlloys

188. NEW MEMBRANE PROCESS FOR IMPROVEDENERGY SAVING SEPARATIONS IN THEPETROLEUM INDUSTRY$0DOE Contact: Doug Hooker (303) 275-4780(Individual) Contact: Dr. John Dorgan

(303) 277-9033

This grant will demonstrate a new membrane formationprocess employing a novel solvent and to demonstrate

that the membranes produced possess superiorproperties when compared to existing materials.

Keywords: Petroleum Refining, Membranes,Separations

189. LOST FOAM CASTING QUANTIFIER PROGRAM$46,058DOE Contact: Steve Sargent (303) 275-4912Industrial Analytics Corporation Contact:

Pat Alexander (865) 482-8424

This grant will prepare a prototype of a production floormachine and demonstrate it use in a castingimprovement program with a major industry partner.Industrial Analytics Corporation is a product and servicesbusiness engaged in the development and marketing ofnon-destructive testing and inspection equipment andanalysis services for the manufacturing industry. Theindustry currently relies on visual inspection of foampatterns pieces to determine quality. The casting ofinferior foam patterns results in defective castings. Eachdefective casting represents a waste of energy. The “LostFoam Casting Quantifier Program” sets objectives,measurable standards, and verifies them using measureddata, the properties of foam patterns may be optimized,production yield can be maximized, quality can beassured, and disputes minimized.

Keywords: Metal Casting, Lost Foam Casting, Non-Destructive Testing

190. ENERGY CONSERVATION WASTE REDUCTIONIN THE PROCESSING OF SOFT (UNFIRED)CERAMIC PARTICLES VIA DYNAMIC CYCLONECLASSIFICATION$93,840DOE Contact: Steve Sargent (303) 275-4912InnovaTech, Inc. Contact: Steve Crouch

(919) 881-2197

This grant will confirm prior bench-scale DCCperformance through the successful scale-up and testingof a full-sized (2 ton/hr) Beta prototype. A market studyand business plan will be produced based on scale-upcosts and performance.

Keywords: Ceramics, Dynamic Cyclone Classification,Soft Ceramic Particles


83

191. SELECTIVE BATCHING FOR IMPROVEDCOMMERCIAL GLASS MELTING$40,000DOE Contact: Gibson Asuquo (303) 275-4910Alfred University Contact: Diane Vossler

(607) 871-2487

This grant will demonstrate that selective pre-batching ofraw material feed stocks prior to their introduction to theglass furnace will reduce initial viscosity differences andminimize the tendency for segregation between alkali andalkaline earth salts in the batch. Several binarycomponents will be batched and heated to determine lowtemperature segregation tendencies. A 10 percentreduction in furnace residence time, resulting in industry-wide savings of 20 trillion Btu/yr. (16 billion cubic feet ofnatural gas/yr.) is anticipated. A corresponding reductionin energy consumption and CO, CO2, and NOx isexpected.

Keywords: Glass Melting, Alkali, Alkaline, Earth Salts

192. NEW “DIRECT POUR IN-MOLD” (DPI)TECHNOLOGY FOR PRODUCING DUCTILE ANDCOMPACTED GRAPHITE IRON CASTINGS$195,881DOE Contact: Steve Sargent (303) 275-4912Comanche Technologies Contact:

Jay R. Hitchings (610) 269-6241

This grant will demonstrate and invention combining twoproved foundry techniques: in-mold magnesiumtreatment, and the direct pour method, to produce aunique solution to several problems associated withstandard in-mold treatment. It also adds considerablebenefits of direct pour. The scope of work is quite broad,combining both the engineering of the container and themarketing work required to understand the optimal launchprice as well as best channel(s) to market. DPI containersprovide energy savings of 13.3 percent over comparabletreatments, increased mold yields, and very highmagnesium recovery, zero magnesium fumes, and nopost inoculation are required.

Keywords: Pour In Mold, Graphite Iron Casting,Magnesium Treatment

193. CLEAN PRODUCTION OF COKE FROMCARBONACEOUS FINES$200,000DOE Contact: Doug Hooker (303) 275-4780Combustion Resources Contact: Craig Eatough

(801) 370-0654

This grant will demonstrate the refine material andprocess requirements to improve economic benefits andexpand prior work on the technology through successfulprototype testing of both metallurgical and foundry coke

products. The initial market study and business plan willbe refined based on this work. A 500,000-ton/year plantthat utilizes the new process uses almost six times thisamount of waste coke fines as feedstock.

Keywords: Foundry Coke, Carbonaceous Fines, RefineMaterials, Metallurgical


194. DEVELOPMENT OF PHOSPHORS FOR USE INHIGH-EFFICIENCY LIGHTING AND DISPLAYS $0 DOE Contact: Andy Trenka (303) 275-4745 Brilliant Technologies, Inc. Contact:

Douglas Kezler (541) 737-6736

This grant will demonstrate and develop new phosphorsfor use in high-efficiency, LED-activated lamps anddisplays, providing improved color rendering andsignificant energy savings. The phosphors will provide forthe first time a means to produce true tri-chromatic whitelight under LED excitation.

Keywords: Phosphors, LED-Activated Lamps, LED

195. ENERGY SAVING LIGHTWEIGHT REFRACTORY$0DOE Contact: Gibson Asuquo (303) 275-4910 Silicon Carbide Products, Inc. Contact:

David Witmer (607) 562-7585

This grant will demonstrate and develop a newmanufacturing technique to produce a unique siliconcarbide based material that has high strength, increasedhigh temperature qualities, and will cost less tomanufacture. In addition, the new material has showngreat promise in molten aluminum applications.

Keywords: Refractory, Silicon Carbide

196. HIGH INTENSITY SILICON VERTICAL MULTI-JUNCTION SOLAR CELLS $0DOE Contact: Lizana Pierce (303) 275-4727 PhotoVolt, Inc. Contact: Bernard Sater

(440) 234-4081

This grant will demonstrate and develop a low-cost, high-volume fabrication process for high intensity verticalmulti-junction (VMJ) solar cells and demonstrateperformance viability in solar concentrators. The uniquefeatures of the VMJ cell make it capable of more efficient


84

operation at higher intensities than other siliconconcentrator solar cell designs.

Keywords: Solar Cells, Solar Concentrators,Photovoltaic

197. A LOW ENERGY ALTERNATIVE TOCOMMERCIAL SILICA-BASED GLASS FIBERS $0DOE Contact: Gibson Asuquo (303) 275-4910 MO-SCI Corporation Contact: Ted Day

(573) 364-2338

This grant will demonstrate and develop high strength,iron phosphate glass fibers for composites and otherproducts in the transportation, aircraft, and chemicalindustries. Iron phosphate glasses have a chemicaldurability that exceeds many commercial silica-basedglasses and can be melted 3 to 20 times faster attemperatures 400-600o C lower than commercial boro-alumino-silicate glass.

Keywords: Glass, Iron Phosphate Glass Fibers, Silica-Based Glass Fibers

198. A VIABLE INERT CATHODE FOR SMELTINGPRIMARY ALUMINUM$0 DOE Contact: Keith Bennett (303) 275-4905 PRACSOL, LLC Contact: Robert Rapp

(614) 292-6178

This grant is aimed at developing sufficientexperimentation to prove the feasibility of a net shapemethod of manufacture and the effective properties of aporous TiB2 body suitable as an inert cathode in the inthe Hall-Héroult cell.

Keywords: Aluminum, Cathode, Inert Cathode,Titanium

199. DEVELOPMENT OF INERT ANODE FOR THEPRIMARY ALUMINUM INDUSTRY$0 DOE Contact: Keith Bennett (303) 275-4905 Energy Research Company Contact:

Robert De Saro (718) 442-2725

This grant will experimentally determine the amount andpurity of the aluminum produced in a bench-scale IonicCeramic Oxygen Generator (ICOG) inert anodeexperiment and to determine anode degradation. TheICOG inert anode uses a crystal lattice to transportoxygen ions from the electrolytic solution where they are

oxidized to diatomic oxygen gas. For this researchproject, the ICOG inert anode will replace the traditionalconsumable carbon anode in this project.

Keywords: Aluminum, Anode, Inert Anode, AnodeDegradation

200. AUTOMATIC EVALUATION OF WOODPROPERTIES$0DOE Contact: Doug Hooker (303) 275-4780 Quantum Magnetics Contact: Erik Magnuson

(858) 566-9200

This grant will determine quantitative, predictive formulasrelating wood properties to the solid-state magneticresonance measurement parameters through thespecies/class categorization. With the project funds, wewill experimentally derive a wood species relationship interms of magnetic resonance signal parameters,sufficient to allow pallet recyclers to sort wood partsknowing that the reassembled pallets will provide serviceat least equal to that of a new pallet from similar speciesmaterial.

Keywords: Pallets, Wood Speciation, MagneticResonance, Wood Sorting

201. ELECTROCHROMIC WINDOW FILM$0DOE Contact: Andy Trenka (303) 275-4745Chameleon Optics, Inc. Contact: Dr. Paul Martin

(215) 387-2717

This grant will demonstrate manufacturing feasibility ofelectrochromic window films and to produce samples forfurther evaluation.

Keywords: Electrochromic Windows, Buildings,Window Film

202. HIGH THROUGHPUT VACUUM PROCESSINGFOR INNOVATIVE USES OF GLASS$123,058DOE Contact: Steve Sargent (303) 275-4912AVA Technologies, Inc. Contact: Kurt Barth

(970) 491-8411

This grant will demonstrate a system with HPD sourcesand glass heaters for processing 1 x 1 foot substrates willbe developed and tested. A belt arrangement similar thatused in the current AVA prototype will be used fortransporting substrates from one process module to thenext. There will be up to seven processing stations in the


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vacuum chamber. The processing of completephotovoltaic devices will also be tested.

Keywords: Glass, Photovoltaic Panels, High PressureDeposition

203. AN INSOLUBLE TITANIUM-LEAD ANODE FORSULFATE ELECTROLYTES$0DOE Contact: Steve Sargent (303) 275-4912 Electrodes International Contact: Alla Ferdman

(847) 465-0785

The grant will develop insoluble anodes forelectrowinning of metals such as copper, zinc, nickel,cobalt, etc. and for electrolytic manganese dioxideproduction. The proposed anodes significantly reducecontamination of the products with lead and can be usedat lower voltage and increased current density, resultingin higher productivity and energy savings up to 25percent.

Keywords: Electrowinning, Anodes

204. NON-INVASIVE ESTIMATION OF DISSOLVEDALUMINA CONCENTRATION IN HALL-HÉROULT REDUCTION CELLS$29,200DOE Contact: Steve Sargent (303) 275-4912 Individual Contact: David Bell (509) 468-0188

This grant will develop a method to identify the dissolvedalumina concentration in the Hall-Héroult reduction cell,using estimated properties of the cell resistancedisturbance caused by the introduction of suspendedalumina particles comprising the normal feed to the cell.The project will optimize this electrochemical processusing digital signal processing technology, to assure theprocess will operate at maximum efficiency. An industry-wide energy improvement of 2 percent current efficiencyis expected.

Keywords: Non-Invasive, Alumina, Hall-Héroult, Cells

205. VISIBLE SPECTRUM INCANDESCENTSELECTIVE EMITTER$197,876DOE Contact: Keith Bennett (303) 275-4905Sonsight, Inc. Contact: Devon R. McIntosh

(301) 283-6250

This grant will design, build, and test a prototype unit of anovel light source that utilizes incandescence with anefficiency and longevity comparable to that of fluorescentlighting. The 18-month project will develop a novelheating arrangement to attain and maintain high, stable

incandescent temperatures, and optically and physicallyoptimize the composite ceramic oxide emitter.

Keywords: Incandescent, Emitter, Spectrum,Fluorescent Lighting, Ceramic Oxide


206. LIGHTWEIGHT AND COST EFFECTIVE CASTALUMINUM DIESEL ENGINE HEAD WITHLOCALIZED REINFORCEMENT$195,881DOE Contact: Steve Sargent (303) 275-4912 Foster-Miller, Inc. Contact: Uday Kashalikar

(781) 684-4125

This grant will produce aluminum gravity cast dieselengine head (and block) components for diesel engineswith performance and weight comparable to that ofcurrent gasoline engines. Highly loaded regions inaluminum gravity castings with metal matrix composites(MMC) will be locally reinforced after being optimized anddemonstrated at the subcomponent level.

Keywords: Cast Aluminum, Diesel Engine Head,Localized Reinforcement


207. FABRICATION AND TESTING OF APROTOTYPE CERAMIC FURNACE COIL$0DOE Contact: Steve Sargent (303) 275-4912 FM Technologies, Inc. Contact: Frederick Mako

(703) 961-1051

This grant will demonstrate a process for joining pairs ofceramic tubes to fabricate furnace coils for ethyleneproduction plants. Ethylene has the greatest annualproduction of any organic chemical and is the numberone consumer of energy in the petrochemical industry.Replacement of metal alloy coils with ceramic coils couldincrease ethylene production by up to 10 percent leadingto substantial energy savings and increased productivity.

Keywords: Ceramic Tubes, Furnace Coils, EthyleneProduction


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208. FLUTED SPIRAL MEMBRANE MODULE FORREVERSE OSMOSIS OF LIQUIDS WITHDISSOLVED AND SUSPENDED SOLIDS$0DOE Contact: Doug Hooker (303) 275-4780 Scinsep Systems Contact: Jatal Mannapperuma

(530) 758-3708

This grant will develop a methodology for the fabricationof the fluted spiral module, produce a prototype module,and test its performance.

Keywords: Fluted Spiral Membranes, ReverseOsmosis, Separations

209. HIGH ENERGY-DENSITY DOUBLE-LAYERCAPACITOR ENERGY STORAGE FORPHOTOVOLTAIC SYSTEMS$158,166DOE Contact: Steve Sargent (303) 275-4912Heliocentric, LLC Contact: Troy Harvey

(801) 427-4748

This grant will scale-up and demonstrate commercial-scale HDLC prototypes, above 1kWh of packagedcapacity. Key objectives include further development andimprovements in electrode composite, trilaminatecomposite, the housing, and parameterization of theHDLC variables. HDLC improves energy storagecharacteristics, reduces embodied energy by6110 kBtu/kWhC, and lowers photovoltaic system life-cycle cost per kilowatt-hour by 3-5 times. It also improvesin-system round-trip energy efficiency by 29-34 percent,and has a 40-60 percent greater available capacity thanlead-acid batteries.

Keywords: Capacitor, Energy Storage, PhotovoltaicSystems, Batteries

210. ENABLING TOOL FOR INNOVATIVE GLASSAPPLICATIONS$119,939DOE Contact: Gibson Asuquo (303) 275-4910Michigan Tech. Univ. Contact: Murray Gillis

(906) 487-1820

This grant will develop an abrasive waterjet cuttingsystem, using glass as the abrasive media, for new andexisting glass production facilities. Objectives include thescaling up and refinement of a circuit used for theproduction of glass abrasives, the optimization of cuttingmethods, and utilization of the resulting glass wastestream as filler in various polymers. It is conceivable thata reduction of 10 percent to 15 percent in the size offeedstock will result.

Keywords: Glass, Abrasive Waterjet Cutting, Polymers

INSTRUMENTATION AND FACILITIES

211. DEVELOPMENT OF AN INNOVATIVE ENERGYEFFICIENT HIGH TEMPERATURE NATURALGAS FIRED FURNACE$0DOE Contact: Keith Bennett (303) 275-4905 Procedyne Corp. Contact: Vijay Shroff

(732) 249-8347

This grant will improve the efficiency of gas-fired furnacesused for heat-treating, metal recovery, and inorganicchemical production. Compared to current gas-firedheating mantles, the proposed furnace can save up to 70percent of natural gas fuel and achieve a highercombustion efficiency for a given combustion gasdischarge temperature.

Keywords: Heat Treating, Gas-Fired Furnaces

212. IMPROVED PROCESS CONTROL OF WOODWASTE FIRED BOILERS$0DOE Contact: Jim Spaeth (303) 275-4706Process Control Solutions Contact: Rick Meeker

(850) 385-5100

This grant will characterize the wood-waste boiler controlinter-relationships and constraints through data collectionand analysis, design an improved control architecture,develop and test an appropriate model predictive controland optimization algorithm, and develop and test aprocedure for reproducing the approach and deriving thebenefits on all similar pulp and paper wood-waste boilers.

Keywords: Wood-Waste Boiler, Pulp and PaperBoilers, Boiler Architecture

213. DEVELOPMENT OF ENVIRONMENTALLYBENIGN MINERAL FLOTATION COLLECTORS$0DOE Contact: Steve Sargent (303) 275-4912Versitech, Inc. Contact: Sharon Young

(520) 742-9457

This grant will determine the precise factors that allow thenon-sulfur containing triglycerides to collect sulfideminerals, particularly copper, as well or better than theconventional sulfur-containing collectors. The physicaland chemical properties of the oils will be measured to tryto obtain a correlation between one or more properties orcompositions and mineral recoveries. To assist in thiseffort, artificial oils composed of one type of triglyceridewill be tested in order to try to elucidate the bestcomposition for a particular type of ore.

Keywords: Mining, Mineral Flotation, Sulfides, Copper


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214. THERMOPHOTOVOLTAIC ELECTRIC POWERGENERATION USING EXHAUST HEAT IN THEGLASS, STEEL AND METAL-CASTINGINDUSTRIES$0DOE Contact: Gibson Asuquo (303) 275-4910 JX Crystals, Inc. Contact: Jason Keyes

(425) 392-5237

This grant will build a thermophotovoltaic (TPV) cylinderheated externally with a water-cooled TPV array inside.JX Crystals has developed TPV systems with burnersthat heat an emitter surrounded by TPV cells. For thisproject, the heat source is the exhaust stream from anindustrial process, so the TPV geometry will be invertedand the circuits will be placed inside an emitter tube. JXCrystals plans to demonstrate the production of1.5 W/cm2 of electricity and a TPV efficiency of20 percent. Additionally, Enron and other companies inthe glass, steel and metal casting industries will becontacted in order to familiarize them with TPV and toenlist their support in integrating TPV technology intotheir processes.

Keywords: Thermophotovoltaic, Photovoltaic, GaSbCells, Ceramic Emitter

215. A HOTEYE™ BASED COORDINATEMEASURING MACHINE FOR THE FORGINGINDUSTRY$69,744DOE Contact: Steve Sargent (303) 275-4912OG Technologies Contact: Tzyy-Shuh Chang

(734) 769-8500

This grant will develop a 3 dimensional measurementsystem for the domestic forging industry based onHotEye™. This technology will allow high definitioncamera to accurately image a red-hot object. The projectmarries conventional Coordinate Measurement Machine“CMM” technology to HotEye™ technology to permit theaccurate measurement of forged parts while they are athigh temperature. Being able to take such measurementswill dramatically reduce the amount of scrap produced bythe domestic forging industry. This industry wastes asignificant amount of energy because of the high rate ofscrap it produces.

Keywords: Forging, HotEye, Coordinate Measurement

216. DEVELOPMENT OF A HIGH-FREQUENCYEDDY-CURRENT SEPARATOR$72,058DOE Contact: Steve Sargent (303) 275-4912EMPS Corporation Contact: Stephen Smoot

(801) 582-7600

This grant will confirm prior bench scale testing of thehigh-frequency eddy-current separator through thesuccessful scale-up and test of a prototype-size unit. Theengineering prototype will be demonstrated oncontaminated foundry sand at the Eriez test facilities inErie, PA and on magnesium smut at the Interworldmagnesium recovery facility. The initial market study andbusiness plan will be refined based on the results of theprototype unit testing and demonstration.

Keywords: Foundry Sand, Foundries, Separations,Magnesium Smut

217. INTEGRATED ACOUSTIC KILN MONITOR TOGUIDE ACCELERATED DRYING OF WOOD$108,058DOE Contact: Keith Bennett (303) 275-4905 U.S. Natural Resources Contact: Mark Schafer

(610) 832-2100

This grant will complete two pre-production prototypes ofthe Acoustic Kiln Monitor and demonstrate them in acommercial environment. The ultimate goal is to helpoperators accelerate lumber drying to its optimalendpoint, while minimizing damage to the wood causedby speeding the drying process.

Keywords: Forest Products, Sensors and Controls,Lumber Drying, Kiln Monitor

218. SYSTEM FOR DETECTION AND CONTROL OFDEPOSITION IN KRAFT RECOVERY BOILERSAND MONITORING GLASS FURNACES$113,058DOE Contact: Doug Hooker (303) 275-4780 Combustion Specialists Contact:

George Kychakoff (425) 432-1589

This grant will finish the development of a system tomonitor and control deposition on the pendant tubes ofrecovery boilers and investigate the applicability of thesystem to utility boilers and glass furnaces.

Keywords: Forest Products, Kraft Recovery Boilers,Sensors and Controls


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219. DEVELOPMENT AND COMMERCIALIZATION OFBIOPULPING$25,058DOE Contact: Doug Hooker (303) 275-4780 Biopulping International Contact: Masood Akhtar

(608) 231-9484

This grant will confirm prior bench-scale testing of theproposed technology through the successful scale-up ofthe prototype-size in cooperation with a mill.

Keywords: Forest Products, Pulping, Fungus, WoodChip Penetration

220. DEVELOPMENT OF A LOWER pH COPPERFLOTATION REAGENT SYSTEM$108,308DOE Contact: Steve Sargent (303) 275-4912Versitech, Inc. Contact: Sharon Young

(520) 742-9457

This grant will develop a system of reagents that canallow mill flotation operators to reduce or eliminate theamount of lime that they use. The system would be pilotplant scale tested to identify and solve any problems thatare caused anywhere in the flotation circuit. Possibleproblem areas include froth bed height in the roughers orthe cleaners, recovery losses in the cleaners, and tailflocculation. Froth height problems can be overcome byfrother modifications. Loss of recovery in the cleaner canbe handled by collector modification, while theflocculation of the tailing can be achieved by changingthe flocculent.

Keywords: Mining, Copper, Flotation, Collectors,Flocculation

221. MONITORING OF REFRACTORY WALLRECESSION USING RADAR TECHNIQUES$40,000DOE Contact: Gibson Asuquo (303) 275-4910Univ. of Missouri-Rolla Contact:

Dr. Robert Moore (573) 341-6326

The project will develop an effective monitoring systemthat enables glass melters to be managed for optimumefficiency and longevity. The new system will bedesigned to maximize use and save substantialmaterials, process energy, and downtime. Research willfocus on the recession of refractory walls in contact withcommercial glasses and on the adaptation of a specialradar technology, the Frequency-Modulated Continuous-Wave Technique, which utilizes simple microwavehardware.

Keywords: Monitoring, Wall Recession, RadarTechnology, Glass

222. MONITORING OF REFRACTORY WALLRECESSION USING HIGH TEMPERATUREIMPACT-ECHO INSTRUMENTATION $39,939DOE Contact: Gibson Asuquo (303) 275-4910University of Dayton Contact: Claudette Groeber

(937) 229-2919

This grant will design and build several high temperatureimpact-echo transducers to demonstrate their use formeasuring the wall thickness of refractory walls used inglass furnaces. Equipment developed will be a pre-prototype system, which may be suitable for industrialtrials with only minor refinements.

Keywords: Monitoring, Wall Recession, Impact-EchoInstrumentation, Glass

223. FIBER SIZING SENSOR/CONTROLLER FOROPTIMIZING GLASS AND POLYMER FIBERMANUFACTURING PROCESSES$199,260DOE Contact: Gibson Asuquo (303) 275-4910Powerscope, Inc. Contact: Amir Naqwi

(612) 331-4247

This grant will develop a controller for optimizing glassand polymer fiber manufacturing that utilizes real-time,on-line measurements of fiber diameter distribution bylaser, used for process monitoring and control. Theproposed method uses a collimated laser light beam andan array of ring detectors to collect light diffracted byfibers. Project work involves adaptation of existingtechnology to fiber sizing and extensive field-testing.

Keywords: Fiber Sensor, Glass Fiber, Polymer Fiber,Laser Light Beam


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NATIONAL INDUSTRIAL COMPETITIVENESSTHROUGH ENERGY, ENVIRONMENT ANDECONOMICS (NICE3)DOE Contact: Lisa Barnett (202) 586-2212


224. PRESSURIZED OZONE MEMBRANEULTRAFILTRATION METHODOLOGY FOR TDSREMOVAL IN PAPER MILL PROCESS WATERFOR ENERGY SAVINGS, PRODUCTIONEFFICIENCY, AND ENVIRONMENTAL BENEFITS$0DOE Contact: David Godfrey (404) 562-0568Linpac Paper Contact: Joe Gasperetti

(864) 463-9090SC Energy Office Contact: Jean-Paul Gouffray

(803) 737-8030

This grant will demonstrate the pressurized ozonemembrane ultrafiltration system, from the prototype-sizedunits, to a production scale commercial demonstrationsize unit. The project will show that TDS removal can beconducted efficiently and create energy, waste, andeconomic savings.

Keywords: Total Dissolved Solids, Paper Mill,Pressurized Ozone MembraneUltrafiltration, Process Water

225. NEW EFFICIENT AND SAFE DIRECTHYDROGEN PEROXIDE PROCESS$390,000DOE Contact: David Godfrey (404) 347-7140Princeton Advanced Technology Contact:

John Allen (404) 657-7442

This grant will develop a program to build and operate thefirst commercial unit, where the process can besuccessfully operated and hydrogen peroxide made forend application testing. The intent is to build a successfulcommercial demonstration unit to supply customers withhydrogen peroxide.

Keywords: Hydrogen Peroxide, Commercial HydrogenPeroxide Process

226. ENERGY-SAVINGS REGENERATION OFHYDROCHLORIC ACID PICKLING LIQUOR $0 DOE Contact: Scott Hutchins (617) 565-9765 Green Technology Contact: Doug Olsen

(914) 855-0331 CT Bureau of Waste Management Planning &

Standards Division Contact: Lynn Stoddard(860) 424-3236

This grant will demonstrate an innovative technology thatregenerates spent hydrochloric acid from steel picklingthat results in 95 percent energy savings, 52 percent costsavings, and 91 percent reduction in CO2 overconventional technologies. This process generates nowastewater or residual waste, and produces significantoperating and capital cost savings in addition to majorenergy savings.

Keywords: Hydrochloric Acid Recovery, Pickle Liquor,Galvanizing

227. DEMONSTRATION OF MAGNETICELUTRIATION TECHNOLOGY FOR CLEAN ANDEFFICIENT PROCESSING IRON ORE$0 DOE Contact: Brian Olsen (312) 353-8579 5R Research Contact: John McGaa

(651) 730-4526MN Dept. Public Service Contact:

Jeremy DeFiebre (651) 297-1221

This grant will demonstrate an improved mineralprocessing technology known as "magnetic elutriation"which increases selectivity when weakly magnetic tailingsare separated from magnetic iron ores. This patentedprocess produces yields of 99 percent magnetic ironrecovery, while eliminating the need for chemicals usedin conventional separation practices. Industry wide, thisinnovation will reduce chemical use by 1700 tons andsave 170 GWh of electrical energy each year.

Keywords: Mining, Magnetic Elutriation, MineralProcessing

228. COMMERCIAL SCALE DEMONSTRATION OFBIOPULPING: A NEW ENERGY-EFFICIENT &ENVIRONMENTALLY BENIGN TECHNOLOGYFOR PAPERMAKING$468,000DOE Contact: Brian Olsen (312 )886-8579 Biopulping International Contact: Masood Akhtar

(608) 221-2514 WI Dept. of Administration Contact:

Preston Schutt (608) 261-8658

This grant will successfully scale up the technology fromthe prototype size unit to the production scale commercial


90

size unit and run the commercial demonstration longenough to show successful results and the energy,environmental, and economic benefits. The proposedlarge-scale trials will be conducted at Andritz, Springfield,Ohio and SENA, Wisconsin Rapids, Wisconsin with finalgoal of implementing biopulping at the Whiting TMP millin Wisconsin. Additionally, commercialization activitieswill continue during the project period to work towardsuccessful commercialization of the technology.

Keywords: Biopulping, Benign Technology,Papermaking, Whiting

229. CATALYTIC CRACKING DEMONSTRATIONPLANT$0DOE Contact: Jack Jenkins (303) 275-4824Process Innovators Contact: Milton Thacker

(801) 943-0241

This grant will demonstrate the Low Profile Fluid CatalyticCracking Unit (LPFCCU) that improves existing FCCUtechnology by incorporating the most currenttechnologies and process advances into a low profilemultiple reactor unit. The catalyst will be regenerated asin a conventional FCC unit and the products will befractionated or separated as in a conventional unit.

Keywords: Fluid Catalytic, Cracking Unit, FCUTechnology, Low Profile Fluid

230. PRODUCTION-SCALE COMMERCIALDEMONSTRATION OF A VANADIUM CARBIDECOATING PROCESS FOR ENHANCING WEARRESISTANCE OF METALS IN STEEL ANDOTHER MANUFACTURING INDUSTRIES$0DOE Contact: Joe Barrett (215) 656-6957 Metlab-Potero Contact: James Coneybear

(215) 233-2600PA Dept. of Environmental Protection Contact:

Calvin Kirby (717) 783-9981

This grant will design, install, optimize and operate aproduction scale system for commercial application of avanadium carbide coating process. In addition to this, theprogram will develop and maintain a database forperformance of the VC coatings used in differentindustrial applications. The database will include bestpractices for applications that will enable the industry toselect and apply the optimum coatings.

Keywords: Vanadium Carbide, Steel, WearResistance, Surface Hardening

231. THE FLEX-MICROTURBINE FOR PECANWASTE: ELECTRICITY AND HEAT IN ANUTSHELL$0DOE Contact Chris Cockrill (816) 873-3299 Flex Energy Co. Contact: Edan Prabhu

(949) 380-4899AZ Dept. of Environmental Quality Contact:

Kathy Charney (602) 207-2254

This grant will demonstrate that the Flex-Microturbine willrun on pecan shells, that the Flex-Microturbine canconsume this residue cost-effectively and cleanlydisplacing expensive electricity, and the waste heat iscapable of drying and pasteurizing the nuts.

Keywords: Micro-Turbine, Low Btu Gas, Pecan Shells,Nut Orchard Processing

232. ULTRA FINE MINERAL RECOVERY PILOTPLANT$271,000DOE Contact: Chris Cockrill (816) 873-3299Graphic Engineering Contact: Ralph Wostenberg

(530) 459-5534CA Energy Commission Contact:

Dennis Fukumoto (916) 653-6222

This grant will demonstrate the use of Ultra Fine MineralRecovery System (UHF) to assure current throughputcapacity while at the same time recovering a much higherpercentage of minus fifty-micron particles.

Keywords: Mineral Recovery, Fine Minerals, UHF


233. INCREASED PRODUCTIVITY AND REDUCEDENERGY CONSUMPTION IN METAL-CASTINGUSING TITANIUM MATRIX COMPOSITETOOLING$395,638DOE Contact: Scott Hutchins (617) 565-9765Dynamet Technology Contact:

Susan M. Abkowitz (781) 272-5967

This grant will demonstration that titanium matrixcomposite tooling materials can be used in the diecasting industry as a liner for shot sleeves By thesedemonstrations energy, environmental and economicdata will be accumulated to substantiate or to modify theexpectations for this technology. By the end of thisprogram, the CermeTi liners and possibly relatedcomponents will be ready for commercialization in the


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industry. The data and experience gained will be used toencourage wide spread commercial use.

Keywords: Die Casting, Shot Sleeves, Titanium Matrix,Metal-Casting, Composite Tooling

234. COATED RECOUPERATOR$0DOE Contact: Brian Olsen (312) 886-8579Alcoa Contact: David Williams (724) 337-2861IN Dept. of Commerce Contact: Niles M. Parker

(317) 232-8939

This grant will demonstrate the full-scale use of acorrosive-resistant coating that extends the operationallife of recuperators used in aluminum melting furnaces.Objectives include achieving a recuperator life of fouryears or more, allow for use of less expensive HLmaterial, and show that a coated standard metallicrecuperator costing $125,000 will last for four years ormore. Operation of a standard Alcoa aluminum furnacewith the novel coating is expected to bring annual energysavings of 5 trillion Btu, a waste reduction of 3,517 tons,and cost savings of $46,147.

Keywords: Recouperator, Corrosive-Resistant Coating,Aluminum Melting Furnace

235. RAPID HEAT TREATMENT OF CAST ALUMINUMCOMPONENTS$0DOE Contact: Brian Olsen (312) 886-8579Technomics Contact: Steve Krause

(612) 475-1752MN Dept. Public Service Contact:

Jeremy DeFiebre (651) 297-1221

This grant will design, build, and operate a full-scalefacility for demonstrating to manufacturers, with their owncast aluminum components, a novel automated in-lineheat-treating and quenching system. This system usesfluidized bed technology that reduces the time required toachieve specifications by 80-90 percent. The system isexpected to cut energy use by 90 percent.

Key words: Heat Treatment, Cast Aluminum,Automated In-Line Heat Treatment

236. HOT MILL TRANSFER BAR EDGE$0DOE Contact: Joe Barrett (215) 656-6957Weirton Steel Contact: Frank Tluchowski

(304) 797-2296

This grant will produce higher quality steel having lessedge related defects using less natural gas andproportionally reducing CO2 and NOx emissions at thefurnaces. The oxy-gas burners and associated

accessories developed by Air Products and Chemicals,Inc. in conjunction with Daniell-United will be installed atWeirton Steel to demonstrate the technology. Based on aplant producing 3 million tons of steel coil annually,natural gas consumption will be decreased by 28 percent,CO2 emission will be cut by 1,310 tons, and strength andductility of the final product is increased compared toconventional heating.

Keywords: Hot Mill, Oxy-Gas Burners, Bar Edge

237. CLEAN, EFFICIENT GLASS PRODUCTIONUSING HIGH LUMINOSITY OXY-GAS BURNERS$343,000DOE Contact: Joe Barrett (215) 656-6957PPG Industries Contact: Robert P. Woelke

(412) 820-8142PA Dept. of Environmental Protection Contact:

Calvin Kirby (717) 783-9981

This grant will scale up and demonstrate the HighLuminosity burner with integrated combustion actuatorsand controllers as the permanent combustion system foran oxy gas fired flat glass furnace and to achievesignificant decreases in energy consumption,improvements in furnace operation, and decreases ingaseous emissions.

Keywords: Glass Production, Oxy-Gas Burners, HighLuminosity

238. PLASTIC MANUFACTURING FROMRECOVERED POST-CONSUMER DURABLEGOODS$0DOE Contact: Chris Cockrill (816) 873-3299MBA Polymer Contact: Laurence Allen

(510) 231-9035NYSERDA Contact: Dana Levy (518) 862-1090

This grant will construct and demonstrate a plant thatsorts various plastics or polymers. The technology utilizesa novel differentiation technology that allows density-based sorting of various plastics to occur. Different typesof plastics or different grades of the same plastic can nowbe efficiently sorted to obtain a pure, singular endproduct.

Keywords: Plastic Manufacturing, Sorting Plastics,Post-Consumer Durable Goods


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239. LIGHTWEIGHT STEEL CONTAINERS$0DOE Contact: Joe Barrett (215) 656-6957Dispensing Container Contact: George Diamond

(908) 832-7882

This grant will demonstrate a thin-walled dispensingcontainer as strong as conventional steel containers thatutilize an average of 1.7 ounces of steel, or a reductionfrom conventional containers of approximately40 percent. Work includes: a) designing bottom shape,b) determining bottom metal thickness and, c) exploringmethods of manufacturing the bottom. Additional work totest various pressurizing agents will be done. For a plantproducing 200 million containers each year, savings willamount to more than 500 billion Btu for large containersand 200 billion Btu for small containers.

Keywords: Thin-Walled Container, Lightweight Steel,Containers


240. DIE CASTING COPPER MOTOR ROTORS$0DOE Contact: Scott Hutchins (617) 565-9765ThermoTrex Contact: John McCoy (619) 646-5403

This grant will demonstrate high temperature, thermalshock resistant materials that withstand the copper motorrotor dye-casting environment for an economicallyacceptable life. A cost effective near-net shape materialforming process, named Chemical Vapor Composites,will be utilized. Substantial energy and waste savings areexpected.

Keywords: Die Casting, Copper Motor, Motor Rotor,Resistant Materials

241. IMPROVEMENT OF THE LOST FOAM CASTINGPROCESS$0DOE Contact: Scott Hutchins (617) 565-9765 GM Contact: Charles Gough (248) 857-2841NYSERDA Contact: Dana Levy (518) 862-1090

This grant will evaluate and improve the Lost FoamCasting Process by applying recently developedmeasurement tools related to characterization of driedcoating thickness and pore size distribution, improvedunderstanding of rheology of coatings, and the ability to

more accurately measure the size and shape of sand asit relates to the casting process.

Keywords: Lost Foam Casting, Metal Casting, ScrapReduction, Sand Casting

242. MICROSMOOTH PROCESS ON ALUMINUMWHEELS$0DOE Contact: Scott Hutchins (617) 565-9765Metal Arts Contact: Stanley Dahle (315) 789-2200NYSERDA Contact: Dana Levy (518) 862-1090

This grant will demonstrate the use of an innovativeelectroless nickel-plating process, using the Microsmoothprocess, a streamlined replacement for conventionalprocess nickel/chrome plating used in aluminum productfinishing. Chemistry will be optimized and protocols willbe tested to determine the best possible product andsystem for demonstration. Using Microsmooth isexpected to reduce energy and chemical usage, thusproviding environmental, economic, and worker healthbenefits.

Keywords: Microsmooth Process, Aluminum Wheels,Nickel-Plating Process

243. ENHANCED APPLICATION CONTROL OF DIECASTING LUBRICANTS$0DOE Contact: Brian Olsen (312) 886-8579N. Amer. Die Casting Assoc. Contact:

Steve Udvardy (847) 292-3600

This grant will utilize a controlled; two-step energy andpollution reducing technique where water is applied tocool die surfaces during die casting operations. Thetechnology will be demonstrated at Spartan Light MetalProducts in Sparta, Illinois. 50 percent of lubricant usedby the old method can be saved, meaning potentialindustry-wide reductions of emissions by 1440 tons, and2880 tons of waste liquid per year. Operation of one diecasting machine with the new technology will save 6billion Btu/year.

Keywords: Application Control, Die Casting,Lubricants, Emissions


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244. COMMERCIAL DEMONSTRATION OF ANIMPROVED MAGNESIUM THIXOMOLDINGPROCESS$0DOE Contact: Brian Olsen (312) 886-8579Thixomat, Inc. Contact: Dr. Ray Decker

(734) 995-5550State of Michigan, Energy Division Contact:

John Trieloff (517) 241-6224

This grant will demonstrate the improved ThixomoldingProcess (semi-solid metal molding), rather than aconventional die-casting foundry operation with theobjective to reduce energy usage by 50 percent, reducescrap recycling by 50 percent, eliminate the application ofglobal warming gas, SF6, eliminate waste slag and drosswith their disposal problems, provide a worker/environmentally friendly process, that can be integratedinto an automated manufacturing cell to produce metaland metal/plastic assemblies, and cut costs by more than20 percent.

Keywords: Magnesium Alloy Molding, Semi-SolidMolding, Net Shape, Scrap Reduction

245. ZERO EMISSION MECHANICAL SEAL WITHINTEGRAL MICRO HEAT EXCHANGER$234,000DOE Contact: Jack Jenkins (303) 275-4824Exxon/Mobil Contact: Karl Simpson

(225) 977-1920LA Dept. of Natural Resources Contact:

Paula Ridgeway (225) 342-2133

This grant will demonstrate the attraction of a mechanicalseal OEM to the commercialization team (which nowconsists of LSU, UK and Mezzosystems) by successfullydemonstrating the reliability and performance of themechanical seal at a major end user facility (ExxonMobil).This industrial application with a light hydrocarbon as theprocess (sealed) fluid will be ideal to demonstrate: 1)heat tolerance; 2) long term reliability; 3) energy impact;4) environmental impact and 5) economic impact.

Keywords: Zero Emission, Mechanical Seal, HeatExchanger, Hydrocarbon

246. DEMONSTRATION OF A THREE-PHASEROTARY SEPARATOR TURBINE $0 DOE Contact: Chris Cockrill (816) 873-3299 Douglas Energy Co. Contact: Lance Hays



This grant will demonstrate a newly developed compactseparator for the petroleum industry which utilizes

previously wasted process energy to generate power andseparate gas, oil, and water. This technology, to bedemonstrated at a Chevron 15,000 barrel per day facility,will substantially improve the efficiency and productivity ofhigh-pressure offshore oil and gas drilling operations.

Keywords: Oil and Gas Production, HydrocarbonSeparation, Petroleum

247. DEMONSTRATION OF A DUAL PRESSUREEULER STEAM TURBINE FOR INDUSTRIALAND BUILDING APPLICATIONS$0DOE Contact: Chris Cockrill (816) 873-3299Douglas Energy Contact: Lance Hays



This grant will demonstrate the Euler Dual PressureSteam Turbine, a unique turbine system that dramaticallyimproves generation efficiency by utilizing energy thatwas previously wasted by releasing it through the letdownvalves of single steam turbine systems. Thedemonstration unit will be installed at the Rolex Buildingin New York City where it will replace a standardgenerating unit and produce more than 200 megawatts ofadditional electricity. Turbine efficiency is expected toincrease to 80 percent, thus doubling what is currentlypossible.

Keywords: Steam Turbine, Dual Pressure, GenerationEfficiency

248. ADJUSTABLE SPEED DRIVES FOR 500 TO 1500H.P. INDUSTRIAL APPLICATIONS$0DOE Contact: Chris Cockrill (816) 873-3299MagnaDrive Contact: Bruce Densmore

(206) 336-5717

This grant will scale-up the 1500 horsepower MagnaDriveAdjustable Speed Coupling System (ASCS) from aworking prototype to the production-scale commercialASCS. MagnaDrive will install this innovative, energyefficient speed control technology at four industrial siteswhere they will be monitored for energy, environmental,and economic benefits. When compared to competingtechnology, the ASCS will save 20 percent of pumpenergy and 15 percent of fan energy consumed duringcontinuous operation.

Keywords: Adjustable Speed, Coupling System,Industrial Applications


94


249. ENERGY CONSRVING TOOL FORCOMBUSTION DEPENDENT INDUSTRIES$0DOE Contact: Scott Hutchins (617) 565-9765 AFR Contact: James Markham (860) 528-9806CT Bureau of Waste Management Planning &

Standards Division Contact: Lynn Stoddard(860) 424-3236

This grant will demonstrate a new, portable, low-cost,energy-efficient multi-gas analyzer for industries utilizingcombustion boiler and turbine systems. This state-of-the-art combustion-tuning tool saves substantial fuel, reducesemissions, and validates pollution abatement/controltechnology.

Keywords: Combustion Tuning, Multi-Gas Analyzer,Boiler, Turbine System

250. AN AUTOMATIC HIGH TEMPERATURE STEELINSPECTION AND ADVICE SYSTEM$500,000DOE Contact: Brian Olsen (312) 886-8579OG Technologies Contact: Terence C. Libby

(734) 769-8500IN Dept. of Commerce Contact: Niles M. Parker

(317) 232-8939

This grant will design and build a production scale HESteelerTM system and install it at the exit of the rod millat Inland Steel's 12" Bar Mill in Indiana. OGT will operatethe system for 180 days, collect and analyze the datafrom the system and work with Inland Steel to determineappropriate process corrections based on the analysis.The objectives will be to demonstrate that the system:1) operates reliably under actual production conditions;2) identifies 99 percent of the surface defects presentduring production; 3) measures the size of the product towithin +/1 percent of bar diameter; and 4) reduces theamount of scrap being produced from 5 percent to2.5 percent.

Keywords: Steel Inspection, Advice System, Rod Mill

251. SUPPORT INSPECTION: A METHOD OFINSPECTING ON-STREAM PROCESS PIPING ATSUPPORT AREAS$0DOE Contact: Jack Jenkins (303) 275-4805 Tubular Ultrasound Contact: David Siverling

(713) 426-1072Texas Natural Resource Conservation

Commission Contact: Jeff Voorhis (512) 239-3178

This grant will demonstrate to the petrochemical industrythe first commercial system to quantify the remaining wallthickness of on-stream piping at pipe supports. The firstSupport Inspection system demonstration will be used fora series of full-scale commercial demonstrations,evaluations, and certifications at world-class domesticpetrochemical facilities.

Keywords: Pipe Support Inspection, Petrochemical,Ultrasound

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OFFICE OF SCIENCE

FY 2002

OFFICE OF SCIENCE - GRAND TOTAL $539,912,655

OFFICE OF BASIC ENERGY SCIENCES $490,258,000

DIVISION OF MATERIALS SCIENCES AND ENGINEERING $490,258,000

Theoretical Condensed Matter Physics 18,007,000Experimental Condensed Matter Physics 33,667,000Materials Chemistry 27,287,000Mechanical Behavior and Radiation Effects 14,530,000X-ray and Neutron Scattering 35,032,000Structure and Composition of Materials 35,168,000Physical Behavior 15,735,000Synthesis and Processing Sciences 14,497,000Engineering Physics 16,464,000Experimental Program to Stimulate Competitive Research 7,679,000X-ray and Neutron Scattering Facilities 268,032,000Nanoscience Centers 4,160,000

OFFICE OF ADVANCED SCIENTIFIC COMPUTING RESEARCH $41,254,655

DIVISION OF TECHNOLOGY RESEARCH $41,254,655

LABORATORY TECHNOLOGY RESEARCH PROGRAM $1,545,000MATERIALS PREPARATION, SYNTHESIS, DEPOSITION, GROWTH OR FORMING $1,020,000

Advanced Processing Techniques for Tailored Nanostructures in Rare-Earth Permanent Magnets (AL 01 02) 198,000

Development of Bismuth-Based Superconducting Wire with Improved Current Carrying and Flux Pinning Properties (ANL 99 15) 96,000

Interplay Between Interfacial and Dielectric and Ferroelectric Behaviors of Barium Strontium Titanate Thin Films (PNL 99 08) 118,000

Advanced Computational Models and Experiments for Deformation of Aluminum Alloys–Prospects for Design (PNL 99 07) 90,000

Near-Frictionless Carbon Coatings (ANL 98 03) 19,000Interfacial Properties of Electron Beam Cured Composites (ORNL 99 08) 105,000Photocatalytic Metal Deposition for Nanolithography (ANL 99 13) 205,000Low-Cost, High-Performance YBCO Conductors (ORNL 01 06) 189,000


Nanofabrication of Advanced Diamond Tools (LBNL 01 03) 150,000Development of a High-Efficiency Rotary Magnetocaloric Refrigerator Prototype

(AL 99 02) 125,000Direct Casting of Titanium Alloy Wire for Low-Cost Aerospace and Automotive

Fasteners (PNL 99 02) 73,000Nonconsumable Metal Anodes for Primary Magnesium Production (ANL 98 05) 110,000Optimized Catalysts for the Cracking of Heavier Petroleum Feedstocks (LBNL 99 01) 67,000

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OFFICE OF SCIENCE (continued)

FY 2002

SMALL BUSINESS INNOVATION RESEARCH PROGRAM $37,722,980


PHASE I $4,174,621

Silicon Carbide High Temperature Dynamic Pressure Gauge 99,632Turbine Blade Emissivity Sensor 100,000Development of Robust NOx Monitor 98,856Amorphous, Non-Oxide Seals, Derived from Organic Precursors, for Solid

Oxide Fuel Cells 97,026Perovskite/Oxide Composites as Mixed Protonic/Electronic Conductors for

Hydrogen Recovery in IGCC Systems 99,980Highly Textured Composite Seals for SOFC Applications 100,000Internal Pipe Repair System 99,929Assure Natural Gas and Oil Pipeline Reliability by Cost-Effective, High-Performance

Thermoplastic Liners 98,802Biomimetic Membrane for Carbon Dioxide Capture from Flue Gas 99,842Catalysts and Membrane for Selective Methane Oxidative Dimerization 100,000High Efficiency Amorphous and Microcrystalline Silicon Based Double-Junction

Solar Cells Made with Very-High-Frequency Glow Discharge 100,000Low-Cost Nanoporous Sol Gel Separators for Lithium-Based Batteries 100,000The Development of a Low-Cost Separator with Improved Performance 99,969New Solid State Lighting Materials 99,957Monomer-Excimer Phosphorescent White OLEDS for General Lighting 100,000White Illumination Sources Using Striped Phosphorescent OLEDs 100,000An Approach for Reducing Wind Turbine Tower Weight by 70 Percent by

Combining an Innovative On-Site Manufacturing Method with a Novel Tower Design 99,702Development of a Low Wind Turbine Blade Making Optimal Use of Carbon Fiber

Composites 99,968Utilization of Isotruss Technology in Taller Wind Turbine Towers 100,000Transformer Ratio Enhancement Experiment for Next Generation Dielectric

Wakefield Accelerators 90,300Inexpensive High Quality Electron Sources 100,000Continuous Formation of Ta Barrier and Cu Sheath of Nb3Sn Subelements 100,000Concentric Tilted Double-Helix Dipole Magnets 99,976Multifilament Extrusion Cuprate Superconductors 92,953Advanced, High-Filament-Count, Nb3Al, Jelly-Roll Strand for Accelerator Applications 100,000Eliminating a Major Cause of Wire Drawing Breakage in A-15 High-Field

Superconductors 100,000Optimization and Commercialization of the Cable-In-Tube Approach to Fabricating

High Performance Nb3Sn Wires 100,000High Current Density (Jc), Low AC Loss, Low Cost Internal-Tin Superconductors 99,968Hybrid Electrochemical - Electrolytic Capacitor for Next-Generation Electron-Positron

Linear Collider 99,977Microwave Component Fabrication using the Fast Combustion Driven Compaction

Process 99,784A High Thermal Performance, Self-Contained Heat Extraction System suited to Highly

Distributed Heat Sources, with Premise Based on Ultra-Lightweight Considerations 99,797Cylindrical Electrode-Less Gas Electron Multiplier 99,324Micro-Photomultiplier Array 100,000Electrically Medicated Microetching Manufacturing Process to Replace Emersion and

Spray Etching 99,859Radiation Hard Lead Zirconium Titanium (PZT) for Ferroelectric and Plezoelectric Devices 99,920

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FY 2002

SMALL BUSINESS INNOVATION RESEARCH PROGRAM (continued)

DEVICE OR COMPONENT FABRICATION, BEHAVIOR OR TESTING (continued)

PHASE I (continued)

Innovative Helium-Cooled Tungsten PFCs 100,000Insulators and Materials for Close-Spaced Thermoelectric Modules 99,999Separation and Enrichment of Xenon in Air 100,000A Small Seismic Accelerometer Utilizing Single Crystal Piezoelectric Material 99,591High Performance Thermo-Electrically-Cooled LWIR Mercury Cadmium Telluride

Detectors 100,000Nano Liter Scale Blood Sampling and Analysis System 100,000VEGF-Based Delivery of Boron Therapeutics 99,510

PHASE II (FIRST YEAR) $4,810,964

A High-Power, Ceramic, RF Generator and Extractor 375,000KA-Band RF Transmission Line Components for a High-Gradient Linear Accelerator 375,000A Method to Increase Current Density in a Mono Element Internal Tin Process

Superconductor Utilizing ZrO2 to Refine the Grain Size 374,988Hermetic Metallization of Aluminum Nitride for Radio Frequency Devices 374,993A Liquid-Desiccant Heating/Cooling System Powered by Solar Energy 374,482Truss-Integrated Thermoformed Ductwork 375,000Novel Membrane Reactor for the Desulfurization of Transportation Fuels 375,000Low Emission Diesel Engines 375,000Low-Cost, Large-Membrane-Area Modules for Gas Separation 311,764Novel Nano-Structured Catalyst for Steam Gasification of Carbonaceous Feedstocks 375,000Amened Silicate Sorbents for Mercury Removal from Flue Gas 375,000Control of Catalyst Poisons from Coal Gasifiers 375,000High-Temperature Highly-Efficient Ceramic Heat Exchanger 374,737

PHASE II (SECOND YEAR) $8,459,941

Non-Linear Optical Devices for High Performance Networking, Computing and Telecommunication Routing and Modulating 375,000

Advanced Geothermal Optical Transducer (AGOT) 325,879Fast-Response, Two-Dimensional Detector for Epithermal Neutron Detection with

Adjustable Shape 374,999Ceramic Appliques for the Production of Supported Thin-Film Catalytic Membrane

Reactors 300,000Affinity Ceramic Membranes with Carbon Dioxide Transport Channel 300,095Photocatalytic Membranes for Producing Ultrapure Water 300,000Novel Membrane Reactor for Fischer-Tropsch Synthesis 300,000Fast, Low-Noise Readout Chip for Avalanche Photodiode Arrays for Use in

Positron-Emission Tomography Imaging 340,000Miniature Electrochemical Carbon Dioxide Detector 338,128An Innovative Ultramicroelectrode Array for Field-Deployable Trace Metal Analysis 340,000Novel Joining Technique for Oxide-Dispersion Strengthened Iron Aluminide Alloys 375,000A Metallic Interconnect for Intermediate Temperature, Planar, Solid Oxide Fuel Cells 325,000Tailorable, Inexpensive Carbon Foam Electrodes for High-Efficiency Fuel Cell and

Electrochemical Applications 375,000Advanced Cathode Structure for Oxygen Reduction in Polymer Electrolyte Membrane

Fuel Cells 350,000

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FY 2002



PHASE II (SECOND YEAR) (continued)

Efficient Incandescent Lighting Based on Selective Thermal Emitters 350,000‘On Chip' Smart Sensor Array and Control Teleplatform for Thermophotovoltaic Cell

Manufacturing Applications 350,000Infrared Focal Plane Array with Fast Shuttering 375,000Linear Avalanche Photodiode Detector Arrays for Gated Spectroscopy with Single

Photon Sensitivity 375,000Development of a Large-Area Mercuric Iodide Photodetector for Scintillation

Spectroscopy 374,285Segmented, Deep-Sensitive-Depth Silicon Radiation Detectors 366,561Micromachined Silicon, Large Area X-Ray Detector 374,994Cost-Reduction Techniques for Powder-in-Tube Niobium-Tin Superconductors 300,000Flexible Niobium-Tin Cables Suitable to React-then-Wind Approach to Fabricating

Accelerator Magnets 250,000Novel Avalanche Photodiode Arrays for Scintillating Fiber Readout 375,000Manufacturing of Robust Ceramic/Metal Joints for Alkali Metal Thermalto Electric

Converters 250,000


PHASE I $797,701

Multilayer Composite Membranes for Upgrading Acid-Rich Natural Gas 100,000Low-Temperature, Solid Oxide Fuel Cell Cathode Development 99,694Use of Graphite Nanofibers as a Catalyst for the Synthesis of Styrene 100,000Modeling of Copper-Indium-Gallium Diselenide for Advanced Thin-Film

Photovoltaic Devices 100,000Stabilized Lithium Manganese Oxide Spinel Cathode for High Power Li-Ion Batteries 98,055A Multi-Megawatt Continuous Wave RF Window for Particle Accelerator Applications 100,000An IR Imaging and Spectral Diagnostic System for Alcator C-Mod 99,952A Solid-State Irradiance Calibrator for Field Use 100,000


Doppler Laser Radar for Non-Intrusive Liquid Metal Flow Characterization 371,942Multi-Megawatt Circulator for TE01 Waveguide 125,000Active Vibration Control of NLC Magnets 375,000An Electrical Condition Monitoring Approach for Wire and Cable 300,000X-Ray Diagnostics for High-Temperature Superconductor Processing 375,000Non-Invasive Techniques to Study Local Passivity Breakdown of Metal Alloys

in Aqueous Media 372,896Microelectrode Array for Electrochemical Sensing of Localized Corrosion 374,839Intelligent Probes for Enhanced Non-Destructive Determination of Degradation

in Hot-Gas-Path Components 375,000

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FY 2002


MATERIALS PROPERTIES, BEHAVIOR, CHARACTERIZATION OR TESTING (continued)

PHASE II (SECOND YEAR) $700,000

Utilization of Hydrocarbon Fuels in Low-Temperature Solid Oxide Fuel Cells 375,000Thin Alternatives to Braided Glass Insulation for Low-Temperature

Superconducting Wire 325,000


PHASE I $4,298,911

Embedded Sensors in Turbine Systems by Direct Write Thermal Spray Technology 99,769Contamination Resistant Anodes for Intermediate Temperature Solid Oxide Fuel Cells 99,998CU-SDC Nanostructural Electrodes as Coking-Resistant Anodes for intermediate-

Temperature SOFCS 100,000Low-Cost Protective Layer Coatings on Thermal Barrier Coatings via CCVD 100,000A Commercially Viable Carbon Molecular Sieve Membrane for Subquality Natural Gas 100,000Catalyst to Improve Small-Scale Claus Plants 100,000LSGM Based Composite Cathodes for Anode Supported, Intermediate

Temperature (600-800 degrees C) Solid Oxide Fuel Cells (SOFC) 99,953Advanced Structural Carbon-Supported Catalysts for Industrial Polymer Synthesis 99,999Metal Oxide Catalyst for Methacrylic Acid Preparation via One-Step Oxidation of

Isobutane 99,988Solid-Acid Catalyst for Refinery Alkylation 100,000Structured Catalyst for Exothermic Reactions 100,000Development of Ion Beam Techniques for Layer Splitting of Oxide Materials 99,982A Novel Technique to Produce Ultra-Porous Metallic Foams through Thermal

Reduction of Nano-Particle Oxide 100,000Novel High Temperature Polymer Substrate for Low Cost High Efficiency Thin

Film CIGS Solar Cells 99,728Non-Vacuum Techniques for Front and Back Contacts for CIGS Solar Cells 99,795Transparent Conducting Oxide Films with High Refractive Index 100,000P-Type ZnO Films 100,000An Advanced Cathode Material for Li-Ion Battteries 100,000Polymer and Gel Electrolyte for Lithium Sulfur Batteries 100,000The Development of a Polyvalent Battery System 99,965Synthesis & Integration of Quantum Confined Atom (QCA) Nanophosphor Based Down

Converter for AlInGaN-Based High Luminous Efficiency White-Light LED Lamps 99,933General Illumination Using Dye-Doped Polymer Light Emitting Devices 99,998Nanomaterials-Based Electrodes for High Charge Rate Energy Storage Devices

of HEVs 100,000Supported Urania Catalysts for Fatty Acid Methyl Ester Dehydrogenation 100,000Three-Dimension Woven Carbon-Glass Hybrid Wind Turbine Blades 100,000PIT Nb3Sn Superconducting Strands Based on a Modified Powder/Tube Reaction

Route 100,000Non-Copper Jc of 2800 A/mm2 through Optimization of PIT Nb3Sn Conductor Design 100,000An Elemental Powder Approach for High Performance Nb3Sn Superconductors 100,000Feasibility of Cost Effective, Long Length, BSCCO 2212 Round Wires, for Very

High Field Magnets, Beyond 12 Tesla at 4.2 Kelvin 100,000A New Method for Depositing Niobium Films for Niobium/Copper Cavities 100,000Growth of a New, Fast Scintillator Crystal for Nuclear Experiments 99,997

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FY 2002



PHASE I (continued)

A Superior Scintillator Material for High Resolution X-Ray Detectors 100,000A New Scintillator for Gamma Ray Spectroscopy 100,000Diamond Windows for High Power Microwave Transmission 100,000Radiation Resistant Insulation with Improved Shear Strength for Fusion Magnets 100,000Nanostructured Tungsten for Improved Plasma Facing Component Performance 100,000High-Strength, High-Conductivity Composite for Plasma Facing Applications 100,000Rugged Packaging for Damage Resistant Inertial Fusion Energy Optics 99,922Low Cost Materials for Neutron Absorption in Generation IV Nuclear Power Systems 99,960High Resolution Gamma Ray Spectrometer for Nuclear Non-Proliferation 100,000Growth of a New Mid-IR Laser Crystal 99,964Ultrapurification, Crystal Growth, and Characterization of Rare-Earth Doped KPb2Br5

for Mid-Infared Lasers 100,000Induim Arsenide Antimonide Very Long Wavelength Photodiodes for Near Room

Temperature Operation 99,960


Innovative Organic and Inorganic High-Pressure Laminate Insulation for Fusion and Superconducting Magnets 373,651

Inorganic-Organic Hybrid Materials: Diacetylene-Siloxanes as Radiation Resistant Electrical Insulator for Plasma Fusion Confinement Systems 374,999

Ultra-Thin Optical Diagnostic Filters for Plasma Wakefield Accelerators 340,034Enhanced Efficiency Nanowire Photocathode for Large PMTs 375,000Superinsulation for Ductwork 375,000Recycling of Coated Plastics Used in Automotive, IT and Commercial Applications 349,333Two-Step Methane Conversion to Alkynes and Dienes 375,000Improved Buffered Substrates for YBCO Coated Conductors 375,000Low Cost MesoCarbon Micro Bead Anodes for Lithium-Ion Batteries 375,000A Novel Cathode Material for High Power Lithium Rechargeable Batteries 375,000Development of Low-Cost Salts for Lithium-Ion, Rechargeable Batteries 374,850High-Performance Carbon Materials for Ultracapacitors 374,888Synthesis of Bulk Amounts of Double-Walled Carbon Nanotubes 375,000Intermediate Temperature Solid Oxide Fuel Cell Development 374,678Novel Ceria-Based Materials for Low-Temperature Solid Oxide Fuel Cells 375,000

PHASE II (SECOND YEAR) $3,922,654

The Development and Demonstration of Reliable Adherent Metalization of AIN 375,000Novel Lithium-Ion Conducting Polymer Electrolytes for Lithium-Ion Batteries 374,997Synthesis of New Solid Polymer Electrolytes 374,999Membranes for Reverse Organic-Air Separations 300,000Hydrogen Recovery Process Using New Membrane Materials 300,000New Boronated Amino Acids for Neutron Capture Therapy 268,028Low-Cost Arc Process to Produce Single-Walled Nano-Tubes Using Coal-Based

Starting Materials 300,000Novel Catalyst for Carbon Monoxide Removal from Fuel Cell Reformate 355,000A Fast, High Light Output Scintillator for Gamma Ray and Neutron Detection 375,000

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FY 2002



PHASE II (SECOND YEAR) (continued)

In-Situ Electron Beam Processing for Radio Frequency Cavities 300,000An Innovative Fabrication Concept for Niobium-Tin Superconducting Wire 299,630High-Performance Niobium-Tin-Tantalum Superconductors Formed by

Mechanical Alloying and Near-Net Shape Tube Filling 300,000

INSTRUMENTATION AND FACILITIES $2,126,252

PHASE I $628,138

An Inexpensive, Efficient Neutron Monochromator 100,000High Performance Thermal Neutron Detector 100,000Neutron and Electron Beam Instrumentation (MSC P1A20-205) 99,802High Gain, Fast Scan, Broad Spectrum, Parallel Beam Wavelength Dispersive

X-ray Spectrometer for SEM 60,023Advanced X-ray Detectors for Transmission Electron Microscopy 100,000Using Convergent Beams for Small-Sample, Time-of-Flight Neutron Diffraction 98,713Four Probe Stage and Holder for Transmission Electron Microscope 69,600


Sol-Gel Derived Neutron Detector Using a Lithiated Glass 373,920Development of an Ultra-Bright Electron Source for Scanning Transmission

Electron Microscopy 375,000Pixel-Cell Neutron Detector and Read-Out System Meeting Requirements of

Present and Future Neutron Scattering Facilities 374,442Novel Neutron Detector for High Rate Imaging Applications 374,752


PHASE I

LITS-Forming for Pre-Bending of Alumiunum Hydroformed Truck Frames 99,858Development of a New, Low Frequency, Rf-Focused Linac Structure 99,978

SMALL BUSINESS TECHNOLOGY TRANSFER RESEARCH PROGRAM $1,986,675


PHASE I $300,000

Carbon Fiber Composite Aeroelastically Tailored Rotor Blades for Utility-Scale Wind Turbines 100,000

Insulation Coating of Rutherford Cable for Accelerator Applications 100,000Fiber Optic Scintillator System for Detection of Beta Emitters in Groundwater 100,000

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FY 2002

SMALL BUSINESS TECHNOLOGY TRANSFER RESEARCH PROGRAM (continued)


PHASE II (FIRST YEAR) $250,000

Advanced Membrane Technology for Biosolvents 250,000


PHASE I $200,000

Hydroforming of Light Weight Components from Aluminum and Magnesium Sheet and Tube 100,000

Carbon/Glass Hybrid Wind Turbine Blades 100,000


Neutron Scattering Instrumentation for Measurement of Melt Structure 250,000


PHASE I $100,000

Waveshifters and Scintillators for Ionizing Radiation Detection 100,000


Virtual-Impact Particle Sizing for Precursor Powders of Nb3Sn and Bi-2212 Superconductors 164,032

Innovative Processing Methods for Superconducting Materials 227,322Oxide Dispersed Nanofluids for Next Generation Heat Transfer Fluids 250,000Plasma Spraying of Nd2Fe12B Permanent Magnet Materials 245,321

OFFICE OF FUSION ENERGY SCIENCES $8,400,000


Vanadium Alloy and Insulating Coating Research 2,000,000Theory and Modeling 1,200,000Ferritic/Martensitic Steel Research 1,900,000SiC/SiC Composites Research 1,500,000Plasma Facing Materials Research 1,800,000

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OFFICE OF SCIENCE

OFFICE OF SCIENCE

The Office of Science (SC) advances the science and technology foundation for the Department and the Nation to achieveefficiency in energy use, diverse and reliable energy sources, a productive and competitive economy, improved health andenvironmental quality, and a fundamental understanding of matter and energy. The Director of Science is responsible for sixmajor outlay programs: Basic Energy Sciences, Fusion Energy, Health and Environmental Research, High Energy andNuclear Physics and Computational and Technology Research. The Director also advises the Secretary on DOE physicalresearch programs, university-based education and training activities, grants, and other forms of financial assistance.

The Office of Science mainly conducts materials research in the following offices and divisions:

Office of Basic Energy Sciences - Division of Materials Sciences and EngineeringOffice of Advanced Scientific Computing Research - Division of Advanced Energy Projects and Technology ResearchOffice of Biological and Environmental Research - Medical Sciences DivisionOffice of Fusion Energy - Division of Advanced Physics and Technology

Materials research is carried out through the DOE national laboratories, other federal laboratories, and grants to universitiesand industry.

OFFICE OF BASIC ENERGY SCIENCES

The Office of Basic Energy Sciences (BES) supportsbasic research in the natural sciences leading to new andimproved energy technologies and to understanding andmitigating the environmental impacts of energytechnologies. The BES program is one of the Nation'sforemost sponsors of fundamental research in broadareas of materials sciences, chemical sciences,geosciences, biosciences, and engineering sciences. TheBES program underpins the DOE missions in energy andthe environment, advances energy-related basic scienceon a broad front, and provides unique national userfacilities for the scientific community.

The program supports two distinct but interrelatedactivities: 1) research operations, primarily at U.S.universities and 11 DOE national laboratories and2) user-facility operations, design, and construction.Encompassing more than 2,400 researchers in 200institutions and 17 of the Nation's premier user facilities,the program involves extensive interactions at theinteragency, national, and international levels. Allresearch activities supported by BES undergo rigorouspeer evaluation through competitive grant proposals,program reviews, and advisory panels. The challenge ofthe BES program is to simultaneously achieve excellencein basic research with high relevance to the Nation'senergy future, while providing strong stewardship of theNation's research performers and the institutions thathouse them to ensure stable, essential researchcommunities and premier national user facilities.

DIVISION OF MATERIALS SCIENCES ANDENGINEERING

The Division of Materials Sciences conducts a broadprogram of materials research to increase theunderstanding of phenomena and properties importantto materials behavior that will contribute to meeting theneeds of present and future energy technologies. TheDivision supports fundamental research in materials atDOE national laboratories and plans, constructs, andoperates national scientific user facilities needed formaterials research. In addition, the Division funds over230 grants, mostly with universities, on a wide range oftopics in materials research.

Fundamental materials research is carried out at elevenDOE laboratories: Ames Laboratory at Iowa StateUniversity, Argonne National Laboratory, BrookhavenNational Laboratory, Idaho National Environmental andEngineering Laboratory, Lawrence Berkeley NationalLaboratory, Los Alamos National Laboratory, NationalRenewable Energy Laboratory, Oak Ridge NationalLaboratory, Pacific Northwest National Laboratory, andSandia National Laboratories in New Mexico andCalifornia, and the Stanford Synchrotron RadiationLaboratory. The laboratories also conduct significantresearch activities for other DOE programs such asEnergy Efficiency, Fossil Energy, Nuclear Energy,Environmental Management and Defense Programs.The Division of Materials Sciences and Engineering alsofunds the University of Illinois Frederick Seitz MaterialsResearch Laboratory. Summaries of the laboratoryportion of the program are available on the World WideWeb at the following address: http://www.sc.doe.gov/bes/dms/Research_Programs/research_program.htm.

Office of Science

104

The performance parameters, economics, environmentalacceptability and safety of all energy generation,conversion, transmission, and conservation technologiesare limited by the discovery and optimization of thebehavior and performance of materials in these energytechnologies. Fundamental materials research seeks tounderstand the synergistic relationship between thesynthesis, processing, structure, properties, behavior,performance of materials of importance to energytechnology applications and recycling of materials. Suchunderstanding is necessary in order to develop the cost-effective capability to discover technologically andeconomically desirable new materials and cost-competitive and environmentally acceptable methods fortheir synthesis, processing, fabrication, qualitymanufacture and recycling. The materials programsupports strategically relevant basic scientific researchthat is necessary to discover new materials andprocesses and to eventually find optimal synthesis,processing, fabricating, and manufacturing parametersfor materials. Materials Science research enablessustainable development so that economic growth can beachieved while improving environmental quality.Description of research supported by various elements ofthe materials program is presented below.

THEORETICAL CONDENSED MATTER PHYSICS

The Theoretical Condensed Matter Physics activityprovides theoretical support for all parts of the MaterialsScience and Engineering Division. Research areasinclude quantum dots, nanotubes and their properties,tribology at the atomic level, superconductivity,magnetism, and optics. A significant effort within theportfolio is the development of advanced computeralgorithms and fast codes to treat many-particle systems.An important facilitating component is the ComputationalMaterials Science Network (CMSN), which enablesgroups of scientists from DOE laboratories, universities,and (to a lesser extent) industry to address materialsproblems requiring larger-scale collaboration acrossdisciplinary and organizational boundaries. The FY 2002funding for this program is $18,007,000 and the DOEcontact is Dale D. Koelling, (301) 903-2187.

EXPERIMENTAL CONDENSED MATTER PHYSICS

The portfolio consists of a broad-based experimentalprogram in condensed matter and materials physicsresearch emphasizing electronic structure,surfaces/interfaces, and new materials. It includes thedevelopment and exploitation of advanced experimentaltechniques and methodology. The objective is to providethe understanding of the physical phenomena andprocesses underlying the properties and behavior ofadvanced materials. The portfolio includes specificresearch thrusts in magnetism, semiconductors,superconductivity, materials synthesis and crystal growth,

and photoemission spectroscopy. The portfolioaddresses well-recognized scientific needs, includingunderstanding magnetism and superconductivity; thecontrol of electrons and photons in solids; understandingmaterials at reduced dimensionality, including thenanoscale; the physical properties of large, interactingsystems; and the properties of materials under extremeconditions. The FY 2002 funding for this program is$33,667,000 and the DOE contact is Dale D. Koelling,(301) 903-2187.

MATERIALS CHEMISTRY

This activity broadly supports basic, exploratoryresearch on the design, synthesis, characterization, andproperties of novel materials and structures. The generalfocus is on the chemical aspects of complex andcollective phenomena that give rise to advancedmaterials. The portfolio emphasizes solid-statechemistry, surface and interfacial chemistry, andmaterials that underpin many energy-related areas suchas batteries and fuel cells, catalysis, friction andlubrication, energy conversion and storage, membranes,electronics and sensors, and materials aspects ofenvironmental chemistry. It includes investigation ofnovel materials such as low-dimensional solids, self-assembled monolayers, cluster and nanocrystal-basedmaterials, conducting and electroluminescent polymers,organic superconductors and magnets, complex fluids,hybrid materials, biomolecular materials and solid-stateneutron detectors. There is an increased emphasis onthe synthesis of new materials with nanoscale structuralcontrol and taking advantage of unique materialproperties that originate at the nanoscale. In this regard,addition of a new Program Manager (A. M. K.) forBiomolecular Materials has added a new dimension tothe scope of Materials Chemistry research activity.Significant research opportunities exist at thebiology/materials science interface since the world ofbiology offers time-tested strategies and models for thedesign and synthesis of new materials—composites andmolecular assemblies with unique properties andspecific functions. A wide variety of experimentaltechniques are employed to characterize these materialsincluding X-ray photoemission and other spectroscopies,scanning tunneling and atomic force microscopies,nuclear magnetic resonance (NMR), and X-ray andneutron reflectometry. The program also supports thedevelopment of new experimental techniques such ashigh-resolution magnetic resonance imaging (MRI)without magnets, neutron reflectometry, and surfaceforce apparatus in combination with variousspectroscopies. The FY 2002 funding for this program is$27,287,000 and the DOE contacts are Richard Kelley,(301) 903-6051 and Aravinda Kini (301) 903-3565.

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MECHANICAL BEHAVIOR AND RADIATION EFFECTS

This activity focuses on understanding the mechanicalbehavior of materials under static and dynamic stressesand the effects of radiation on materials properties andbehavior. The objective is to understand the defect-behavior relationship at an atomic level. In the area ofmechanical behavior, the research aims to advanceunderstanding of deformation and fracture and to developpredictive models for design of materials having desiredmechanical behavior. In the area of radiation effects, theresearch aims to advance understanding of mechanismsof amorphization (transition from crystalline to a non-crystalline phase), understand mechanisms of radiationdamage, predict and learn how to suppress radiationdamage, develop radiation-tolerant materials, and modifysurfaces by ion implantation. The FY 2002 funding forthis program is $14,530,000 and the DOE contact isYok Chen, (301) 903-4174.

X-RAY AND NEUTRON SCATTERING

This activity supports basic research in condensed matterand materials physics using neutron and X-ray scatteringcapabilities primarily at major BES-supported userfacilities. Research is aimed at achieving a fundamentalunderstanding of the atomic, electronic, and magneticproperties of materials and their relationship to thephysical properties of materials. Both ordered anddisordered materials are of interest as are stronglycorrelated electron systems, surface and interfacephenomena, and behavior under environmental variablessuch as temperature, pressure, and magnetic field.Development of neutron and X-ray instrumentation is amajor component of the portfolio. The FY 2002 fundingfor this program is $35,032,000 and the DOE contact isHelen Kerch, (301) 903-2346.

STRUCTURE AND COMPOSITION OF MATERIALS

Structure and composition of materials includes researchon the arrangement and identity of atoms and moleculesin materials, specifically the development of quantitativecharacterization techniques, theories, and modelsdescribing how atoms and molecules are arranged andthe mechanisms by which the arrangements are createdand evolve. Increasingly important are the structure andcomposition of inhomogeneities including defects and themorphology of interfaces, surfaces, and precipitates.Advancing the state of the art of electron beammicrocharacterization methods and instruments is anessential element in this portfolio. Four electron beamuser centers are operated at ANL, LBNL, ORNL, and theFrederick Seitz MRL at the University of Illinois. TheFY 2002 funding for this program is $35,168,000 and theDOE contact is Altaf Carim, (301) 903-4895.

PHYSICAL BEHAVIOR

Physical behavior refers to the physical response of amaterial, including the electronic, chemical, magneticand other properties, to an applied stimulus. Theresearch in this portfolio aims to characterize,understand, predict, and control physical behavior ofmaterials by developing the scientific basis underpin thebehavior, and furthermore, establishing rigorous physicalmodels for predicting the response of materials. Theform of stimuli ranges from temperature, electrical andmagnetic fields, chemical and electrochemicalenvironment, and proximity effects of surfaces orinterfaces. Basic research topics supported includecharacterization of physical properties with an emphasison the development of new experimental tools andinstrumentations, and multi-scale modeling of materialsbehaviors. Specific areas of research include:electrochemistry and corrosion, high-temperaturematerials performance, superconductivity, fuel cells,semiconductors/photovoltaics, and more. The FY 2002funding for this program is $15,735,000 and the DOEcontact is Harriet Kung, (301) 903-1330.

SYNTHESIS AND PROCESSING SCIENCES

Synthesis and Processing Science addresses thefundamental understanding necessary to extend fromdesign and synthesis to the preparation of materials withdesired structure, properties, or behavior. This includesthe assembly of atoms or molecules to form materials,the manipulation and control of the structure at all levelsfrom the atomic to the macroscopic scale, and thedevelopment of processes to produce materials forspecific applications. The goal of basic research in thisarea ranges from the creation of new materials and theimprovement of the properties of known materials, to theunderstanding of such phenomena as adhesion,diffusion, crystal growth, sintering, and phase transition,and ultimately to the development of novel diagnostic,modeling and processing approaches. This activity alsoincludes development of in situ measurementtechniques and capabilities to quantitatively determinevariations in the energetics and kinetics of growth andformation processes on atomic or nanometer lengthscales. The FY 2002 funding for this program is$14,497,000 and the DOE contact is Jane Zhu,(301) 903-3811.

ENGINEERING PHYSICS

Engineering Physics advances scientific understandingunderlying dynamic interactions of multicomponentsystems. Areas of emphasis include microscopic andnanoscale science of the interactions of fluid, organic orbiological materials with each other and with solidsystems and developing the means to advance thecharacterization of the same. Questions of ongoing

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interest include, predicting behavior multi-componentfluids with and without heat transfer, predicting thebehavior of the solid-liquid interface, understanding theinteractions of phonons with secondary phases or microand nanoscale defects in solids, and non-linear behaviorof engineering systems. The FY 2002 funding for thisprogram is $16,464,000 and the DOE contact isTim Fitzsimmons, (301) 903-9830.

EXPERIMENTAL PROGRAM TO STIMULATECOMPETITIVE RESEARCH

Basic research spanning the entire range ofprogrammatic activities supported by the Office ofScience in states that have historically received relativelyless Federal research funding. The DOE designatedEPSCoR states are Alabama, Alaska, Arkansas, Hawaii,Idaho, Kansas, Kentucky, Louisiana, Maine, Mississippi,Montana, Nebraska, Nevada, New Mexico, North Dakota,Oklahoma, South Carolina, South Dakota, Vermont, WestVirginia, and Wyoming, and the Commonwealth of PuertoRico. It is anticipated that states of Delaware andTennessee and US Virgin Islands will become DOEeligible states in FY04. BES manages EPSCoR for theDepartment. The FY 2002 funding for this program is$7,679,000 and the DOE contact is Matesh Varma,(301) 903-3209.

X-RAY AND NEUTRON SCATTERING FACILITIES

This activity supports the operation of four synchrotronradiation light sources and three neutron scatteringfacilities. These are: the Advanced Light Source (ALS) atLawrence Berkeley National Laboratory; the AdvancedPhoton Source (APS) at Argonne National Laboratory;the National Synchrotron Light Source (NSLS) atBrookhaven National Laboratory; the StanfordSynchrotron Radiation Laboratory (SSRL) at StanfordLinear Accelerator Center; the High Intensity FluxReactor (HFIR) at Oak Ridge National Laboratory; theIntense Pulsed Neutron Source (IPNS) at ArgonneNational Laboratory; and the Manuel Lujan Jr. NeutronScattering Center (Lujan Center) at Los Alamos NationalLaboratory.

Under construction is the Spallation Neutron Source(SNS) at Oak Ridge National Laboratory, which is a next-generation short-pulse spallation neutron source that willbe significantly more powerful than the best spallationneutron source now in existence—ISIS at the RutherfordLaboratory in England. On the drawing board is the LinacCoherent Light Source (LCLS) at Stanford LinearAccelerator Center, which is a free-electron laser that willprovide laser-like radiation in the X-ray region of thespectrum that is 10 orders of magnitude greater in peakpower and peak brightness than any existing coherent X-ray light source. The FY 2002 funding for this program is

$268,032,000 and the DOE contact is Pedro A.Montano, (301) 903-2347.

NANOSCIENCE CENTERS

This activity supports construction and the subsequentoperation of Nanoscale Science Research Centers(NSRCs) at DOE laboratories that already host one ormore of the BES major user facilities. Nanotechnology isthe creation and use of materials, devices, and systemsthrough the control of matter at the nanometer-lengthscale, at the level of atoms, molecules, andsupramolecular structures. Nanoscience andnanotechnology will fundamentally change the waymaterials and devices will be produced in the future andsubsequently revolutionize the production of virtuallyevery human-made object. Nano-science will exploreand develop the rules and tools needed to fully exploitthe benefits of nanotechnology. Each NSRC willcombine state-of-the-art equipment for materials nano-fabrication with advanced tools for nano characteriza-tion. The NSRCs will become a cornerstone of theNation’s nanotechnology revolution, covering the fullspectrum of nano-materials and providing an invaluableresource for universities and industries. The FY 2002funding for this program is $4,160,000 and the DOEcontact is Kristin A. Bennett, (301) 903-4269.

OFFICE OF ADVANCED SCIENTIFIC COMPUTINGRESEARCH

TECHNOLOGY RESEARCH DIVISION

LABORATORY TECHNOLOGY RESEARCHPROGRAM

MATERIALS PREPARATION, SYNTHESIS,DEPOSITION, GROWTH, OR FORMING

252. ADVANCED PROCESSING TECHNIQUES FORTAILORED NANOSTRUCTURES IN RARE-EARTH PERMANENT MAGNETS (AL 01 02)$198,000DOE Contact: Samuel J. Barish (301) 903-2917AL Contact: Matthew Kramer (515) 294-0276

High-energy product (BH)max permanent magnets haveenabled critical size and weight reduction in direct-current electric motors with an accompanying increasein energy efficiency. Nd-Fe-B based magnets arecurrently the clear choice for high-value commercialapplications. Two classes of magnets are produced fromthese alloys. While the anisotropic (textured) magnetspossess the highest (BH)max, they are limited to criticalapplications because of their high cost. Bonded magnetsmade from rapidly solidified alloys have significantlylower (BH)max; but in addition to lower cost ofproduction, they offer the ability to produce net shape

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magnets and may easily be incorporated in larger motorsresulting in considerable energy savings. Whileconsiderable progress has been made in controlling therapid solidification process to reproducibly fabricate high-energy product magnet materials, advances have beenlargely empirical with limited fundamental understanding.This project supports the DOE mission in advancedsynthesis and materials characterization technologies.

Recent developments in high-speed imaging techniqueshave documented a number of problems regarding thestability of the melt pool during melt spinning, and theyprovide the tools to address these problems in asystematic manner. A particularly severe problem is theability of the alloy to wet the quench wheel. When themelt pool fails to wet the quench wheel, the lack of astable pool will result in lower yield and inhomogeneoussolidification of the fraction that contacts the quenchwheel. The objective of this project is to determine thefactors controlling wettability, including composition,impurities, and heat flow, using imaging techniques. Inaddition, procedures for processing digital images will bedeveloped so that they may be transferred to the industrypartner. The imaging techniques and the resultingenhanced control of processing will also be applied toproducing anisotropic rapidly solidified permanent magnetpowders. Such powders have the potential to increasethe (BH)max of bonded magnets by a factor of four.

Keywords: Permanent Magnets, Anistropic Magnets,Bonded Magnets (BH)max, RapidSolidification Process, High-Speed ImagingTechniques, Quench Wheel, AnisotropicRapidly Solidified Permanent MagnetPowders

253. DEVELOPMENT OF BISMUTH-BASEDSUPERCONDUCTING WIRE WITH IMPROVEDCURRENT CARRYING AND FLUX PINNINGPROPERTIES (ANL 99 15)$96,000DOE Contact: Samuel J. Barish (301) 903-2917ANL Contact: Victor Maroni (630) 252-4547

Progress in the commercialization of electric powerequipment fabricated with high temperaturesuperconducting materials has been limited byperformance issues associated with the maximumachievable engineering critical current density, Je, inlong-length composite conductor. One of the mostadvanced conductors available today for suchapplications is the silver-clad (Bi,Pb)2Sr2Ca2Cu3Oy (calledAg/Bi-2223) composite in multifilament form. However,the Je of Ag/Bi-2223 at 77 K in magnetic fields of 1 Teslaor more is not presently adequate for most types ofmotors, generators, transformers, current limiters, andrelated power system components. Research is aimed atinvestigating two new pathways to fabricate the next

generation of improved bismuth-based superconductingwire. One pathway is focused on the controlled growth ofstrong flux pinning centers in Ag/Bi-2223 filaments bythe implementation of special heat treatmentprocedures. These create a transient thermodynamicstate that promotes the growth of selected second phasenanocrystallites having the correct size, shape, andspatial distribution to induce strong inter- and intra-granular flux pinning. The second pathway involvesreducing the c-axis blocking layer gap (between CuO2planes) in layered bismuth cuprates by demonstratingfabrication of the silver-clad (Bi,Pb,Cd)1Sr2Ca1Cu2O(M-1212) along lines that have been developed forAg/Bi-2223. The “in-principle” advantage of M-1212 overBi-2223 stems from the shorter (by ~4 D) blocking gap inM-1212 due to fewer atomic layers in the c-axis repeatunit. From preliminary work, there are existing laboratoryscale indications that both pathways can lead tosignificant improvement in the performance of bismuth-based high temperature composite conductors. Theproject extends DOE commitments in characterizationand design of advanced materials for the acceleration ofsuperconducting technologies to U.S. markets.

Keywords: Superconducting Materials, Silver-Clad(Bi,Pb)2Sr2Ca2Cu3Oy

254. INTERPLAY BETWEEN INTERFACIAL ANDDIELECTRIC AND FERROELECTRICBEHAVIORS OF BARIUM STRONTIUMTITANATE THIN FILMS (PNL 99 08)$118,000DOE Contact: Samuel J. Barish (301) 903-2917PNL Contact: Scott Chambers (509) 376-1766

Barium strontium titanate (BST) and related materialsare entering commercial use for integrated circuitmanufacture as conventional materials reach theirfundamental limits. BST films have capacitance,leakage, and related electrical properties that surpassintegrated circuit device requirements. One of the mostimportant steps towards understanding the interplaybetween interfacial properties and dielectric andferroelectric behaviors of BST (Ba1-xSrxTiO3) is thegrowth of high quality BST films on Si substrates.Successful epitaxial growth of crystalline BST on Si(001)is thought to require the formation of a two-dimensionalinterfacial silicide layer involving either Ba or Sr as theinitial step. Bulk thermodynamics suggests that this thinsilicide layer is required to stabilize the interface. Thegoal of the project is to address two specific issues ofsignificant concern in BST thin-film technology: 1) theeffect of interfacial chemistry and stress on the dielectricand ferroelectric properties of BST thin films, and 2)ferroelectric behavior at the nano-scale level. Researchis focused on preparation, isolation, and characterizationof an ultrathin silicide layer using Sr as the alkaline earthmetal. Si(001)-(2x1) surfaces were prepared in ultra high

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vacuum (UHV) by rapid desorption of the native oxidelayer. These surfaces were exposed to Sr from aneffusion cell in an oxide MBE chamber as a function ofevaporation rate, substrate temperature, and total dose.The resulting interfaces were characterized during growthwith reflection high-energy electron diffraction (RHEED),and after growth with low-energy electron diffraction(LEED), X-ray photoemission (XPS), and X-rayphotoelectron diffraction (XPD). Additionally, the team isinitiating STM investigations to further elucidate thisinterface structure. Physical and electrical testing of thesestructures have been performed to determine interfaceroughness, interface layer formation, interface statedensity, dielectric properties (permittivity, leakage, etc.),and stability vs. post-growth processing. This projectsupports DOE’s commitment to basic energy sciences infostering the synthesis, processing, and characterizationof advanced materials.

Keywords: BST Thin Films, Dielectric, FerroelectricMaterials, Interfacial Chemistry

255. ADVANCED COMPUTATIONAL MODELS ANDEXPERIMENTS FOR DEFORMATION OFALUMINUM ALLOYS – PROSPECTS FORDESIGN (PNL 99 07)$90,000 DOE Contact: Samuel J. Barish (301) 903-2917PNL Contact: M.A. Khaleel (509) 375-2438

Dislocations are the basic lattice line defects in crystallinematerials, with defect densities as high as 1015/m2. Thisproject aims at understanding their collective andcomplex nonlinear dynamical behavior by merging a setof highly sophisticated experiments, using computeraided, massive numerical analyses, and experimentaldata. The project impacts future computational andexperimental advances in dislocation theory and elevatesprospects for predictive alloy properties control. Onemotivation for this work is to characterize fabrication anddurability characteristics of aluminum tailor welded blanksin order to demonstrate their viability for high volume, lowcost stamped automotive panels and structures. FiniteElement Modeling is being used to formulate accurateconstitutive relations to allow complete description ofmaterial response during manufacture. Application of thisresearch to manufacture and design of existing and newlightweight Al materials supports DOE’s initiatives in highperformance computing.

Keywords: Aluminum Alloys, Dislocation Phenomena,Predictive Properties Control

256. NEAR-FRICTIONLESS CARBON COATINGS(ANL 98 03)$19,000DOE Contact: Samuel J. Barish (301) 903-2917ANL Contact: Ali Erdemir (630) 252-6571

Numerous industrial applications involve the use ofmechanical devices containing components that slide orroll against one another. The efficiency and durability ofthese components are often limited by the friction andwear properties of the materials used to fabricate thecomponents. For example, Diesel Technology Company(DTC) and Stirling Thermal Motors (STM) developadvanced energy conversion systems and enginecomponents that will contribute significantly to reducingoil imports and improving air quality by reducing engineemissions. Fuel injection systems being designed anddeveloped by Diesel Technology for use in heavy-dutydiesel engines will require tighter tolerances to run onlow-lubricity fuels at higher operating pressures neededto achieve emissions and efficiency goals. Sincematerials used in current fuel injection systems will notsurvive under these aggravated conditions, newmaterials and/or coatings are needed. Similarly, Stirlingengines being designed by Stirling Thermal Motors willoperate under tribological conditions (e.g., speeds,temperatures, loads, and working fluids) not commonlyencountered, and will require advanced materials,coatings, and lubricants to ensure long-term durability.Argonne will work with Front-Edge Technologies (FET)to commercialize Argonne’s technology for fuel injectionsystems and Stirling engine components beingdeveloped by DTC and STM. The objectives of thisproject are to: 1) advance the basic understanding of thephysical/chemical and tribological processes controllingthe friction and wear behavior of the new carbon films 2)demonstrate the ability of these coatings to improve thefriction and wear performance of materials andcomponents being developed by Diesel Technology andStirling Thermal Motors, and 3) demonstrate that thecoating technology can be scaled-up to coat largenumbers of components on a cost-competitive basis. Ifsuccessful, the NFC technology will have a significantimpact not only on the technology being pursued byDTC and STM, but also in other applications found in theaerospace, biomedical, and manufacturing sectors. Itbuilds on expertise at Argonne in tribology, coatings, andmaterials characterization. This project supports DOEmissions in advanced materials and sustainableenvironments, reducing U.S. dependence on foreign oilimports, and improving U.S. air quality. This project wonan R&D 100 Award in 1998.

Keywords: Carbon Coatings, Friction and Wear, FuelInjection, New Materials, Coatings,Tribology

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257. INTERFACIAL PROPERTIES OFELECTRON BEAM CURED COMPOSITES(ORNL 99 08)$105,000DOE Contact: Samuel J. Barish (301) 903-2917ORNL Contact: Christopher Janke (423) 574-9247

Electron Beam curing of composites and adhesives is anonthermal, nonautoclave curing process which offerssubstantially reduced manufacturing costs and curingtimes, improvements in part quality and performance,reduced environmental and health concerns, andimprovements in material handling, as compared toconventional thermal curing. As satisfactory properties ofelectron beam cured composites are achieved, U.S.industry expects rapid implementation of these materialsfor making better, less expensive, and lightweightairplanes, spacecraft, and automobiles. Previousresearch on electron beam cured composites has shownthat interface dependent properties, such as compositeinterlaminar shear strength, are generally lower thanthose of high performance, autoclave cured composites.A primary objective of this project is to determine thechemical, physical, and/or mechanical mechanismsresponsible for poor adhesion between carbon fibers andepoxy resins subjected to electron beam processing.Another important objective is to optimize electron beamcompatible carbon fiber surface treatments, chemicalagents, modified radiation curable epoxy resin systems,and improved fabrication and processing methods forproducing electron beam cured composites havingexcellent interfacial properties. Currently, work is focusedon characterization of the carbon fiber-epoxy resininterface and identification of the critical radiationprocessing parameters that influence the properties ofelectron beam cured composites. Additionally, variouschemical agents, including coupling agents and reactivefinishes, which are specifically designed to improve thefiber-resin adhesion properties, are being evaluated. Theproject complements DOE investments in advancedmaterials research, and research on energy efficiencyand environmental stewardship.

Keywords: Electron Beam Processing, Electron BeamCured Composites and Adhesives

258. PHOTOCATALYTIC METAL DEPOSITION FORNANOLITHOGRAPHY (ANL 99 13)$205,000DOE Contact: Samuel J. Barish (301) 903-2917ANL Contact: Tijana Rajh (630) 252-3542

A major technical impediment for the development ofmesoscopic scale electronic devices is obtainingmolecular scale conducting patterns. Based on theparameters that are optimized in highly efficientphotochemical energy conversion in naturalphotosynthesis, Argonne National Laboratory has

developed a new mask-less photoelectrochemicalmethod for depositing conductive metal patterns withnanometer scale precision. This technology will enablethe rapid prototyping and manufacturing of mesoscopicelectronics and offers the potential of low-cost smallbatch manufacturing and unparalleled levels ofelectronic integration. This new technology is beingused to fabricate miniaturized (ultimate resolution limitof 1 nm) and rugged electrical interconnects andbiomolecular electronic devices on any surface or insolution. This project will enable the 3-D integrationof passive and active components of mesoscopicintegrated conformal electronics. In addition, thetechnology provides a unique advantage comparedto other electronic technologies, because thesemiconductor substrate (precursor) can also performactive function in the bioelectronic device. Conductorprecursors, semiconductor metal oxide nanoparticlesmodified with chelating agents, that bind metal cations(copper, silver, and gold), will be synthesized. Biologicaltemplates will be used to self-assemble conductorprecursors in order to achieve spacial resolutionvia photocatalysis. The fast photoresponse ofsemiconductor nanodots also provides high timeresolution. Based on a fundamental understanding ofelectron transfer reactions in this biomimetic approach,precursor formulations will be developed andcharacterized for photoelectrochemical response, redoxstability, and mechanical properties. Precursors will bedeposited on a range of substrates (silicon, glass,plastic, metals, ceramics, etc.) or in solution. Conductivepatterns formed by catalytic semiconductor assistedsolid state deposition of copper, silver, or gold will bestudied as a function of nanoparticle size, reductiontechnique, and nanoparticle-chelate associationcomplex. Interconnects and biomolecular assemblies willbe studied to ascertain morphology, function, and 3-Dcharacterization as a function of processingmethodology. The technology developed in this projectis an extension of DOE’s efforts to promotecharacterization of materials useful to nanotechnology.

Keywords: Metal Deposition, Nanolithography, SelfAssembly, Photocatalysis

259. LOW-COST, HIGH-PERFORMANCE YBCOCONDUCTORS (ORNL 01 06)$189,000DOE Contact: Samuel J. Barish (301) 903-2917ORNL Contact: Parans Paranthaman

(865) 574-5045

The successful demonstration of high-performanceYBCO (YBCO) coated conductors by various institutionshas generated great interest around the world. Thisproject will support the DOE mission in energyefficiency.

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The objective of this project is to develop materialscience and technology necessary for YBCO coatedconductors on biaxially textured, nonmagnetic, high-strength substrates. Fundamental studies of the growth ofoxide buffers on these nonmagnetic substrates will beconducted. The research goal is to also develop bothvacuum and nonvacuum processes to deposit compatiblebuffers at high rates. These novel substrates will be thefoundation or template upon which the AmericanSuperconductor Corporation will apply YBCO using itsproprietary trifluoroacetate (TFA) solution process.Applications of these superconducting wires include high-efficiency motors, compact generators, undergroundtransmission lines, oil-free transformers, andsuperconducting magnetic storage systems forsmoothing voltage fluctuations in the power grid. TheRolling Assisted Biaxially Textured Substrates (RABiTS)process developed at ORNL will be utilized. ORNL andASC have reported a very high Jc of 1.9 MA/cm2 at 77 Kand self-field on YBCO films grown by their TFA solutionprocess on standard RABiTS architecture of CeO2(sputtered)/YSZ (sputtered)/Gd2O3 (solution)/nickel.However, before scaling up to fabricate long conductorsin a reel-to-reel configuration, several fundamental issueswill be addressed. Nickel is magnetic, which meanssignificant alternating-current losses, and is alsomechanically soft. Hence, the first issue to be addressedis the development of mechanically strong, nonmagnetic,biaxially textured, alloy substrates. The deposition of anepitaxial oxide buffer layer on a nickel-alloy substrate isnon-trivial due to the tendency of alloying elements innickel to form nonepitaxial oxides on the surface of thesubstrate. The second issue to be addressed is thedevelopment of a suitable buffer layer stack for growth ofhigh-Jc YBCO films. The high number of buffer layersincreases the complexity of fabrication and cost of theconductor. A third objective is to simplify the buffer layerstacks. Because radio frequency magnetron sputteringhas limited deposition rates, the fourth issue to beaddressed is the investigation of higher rate processesfor the fabrication of epitaxial oxide buffer layers on thenonmagnetic substrates. In this project, solutions forcritical roadblocks will be addressed to possiblyaccelerate the development and commercialization oflow-cost, YBCO high-temperature superconducting wires.

Keywords: Oxide Buffers, Trifluoroacetate SolutionProcess, RABiTS, Nickel Alloy Substrate,Radio Frequency Magnetron Sputtering

DEVICE OR COMPONENT FABRICATION,BEHAVIOR OR TESTING

260. NANOFABRICATION OF ADVANCED DIAMONDTOOLS (LBNL 01 03)$150,000DOE Contact: Samuel J. Barish (301) 903-2917LBNL Contact: Othon Monteiro (510) 486-6159

This project will investigate and develop fabricationprocesses for diamond tools and evaluate these tools inactual micromachining operations. The primary use ofthese tools will be for the repair of masks used insemiconductor processing. No technology is presentlyavailable for the repair of defects in masks to be used forthe next generations (critical dimension of 0.13 mm andbelow). Nanomachining can be used for such repairs,and it is regarded as the only technique capable ofrepairing masks for deep ultraviolet lithography. Thediamond tools will be manufactured by plasma-assistedchemical vapor deposition (CVD) of diamond onpreformed molds, which are etched off after thedeposition is completed. Silicon processing technologywill be used to prepare the molds to be filled withdiamond. Diamond is the most promising material forsuch tools because of its superior mechanical propertiesand wear resistance. This project supports the DOEmission in advanced materials.

The major objective of this project is the development ofdiamond tools (tips) to be used in micromachining andnanomachining operations using scanning-probetechnology. The primary application of these tools will bein the repair of masks for the semiconductor industry.Industry and government groups, such as InternationalSematech, regard mask repair as absolutely critical tothe ability to continue to advance semiconductorperformance and device density. LBNL is interested inexpanding the applications of CVD diamond to themanufacturing of microsize and nanosize mechanical,electronic, or optical devices. General Nanotechnologyis directly interested in bringing the CVD diamondtechnology to the mask repair tools to be used in thelithography of circuits in the next several generations(critical dimensions below 130 nm). The project teamintends to develop a manufacturing process to producereliable and reproducible diamond tools and fullycharacterize these tools with regard to their performancein mask repair. The manufacturing process will be basedon plasma-assisted CVD on prefabricated molds; forsome special applications, final shaping processes willalso be developed. The manufacturing process shall becapable of preparing those tool-bits on 4-in. siliconwafers, with diamond deposition rates of 1 to 2 :m/h,which is sufficient to guarantee the economic feasibilityof the fabrication technique. In addition, the processshall be able to prepare tools (diamond tips) withdifferent angles of attack and tip radii down to 2 nm.

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Mechanical toughness and hardness should beoptimized, and wear rates of the most common materialsused in lithographic masks shall be fully characterized, aswell as the wear rate of the tools.

Phase I (Introductory Studies) has been completed. Themajor parameters affecting nucleation density are theexistence of seed layer and the application of biasvoltage. A diamond deposition process that makes use ofthe former has been developed at LBNL and has beenused to prepare the initial samples. Implementation of thecapability of biasing the substrate is being implementedto the existing diamond deposition chamber: design ofthe required components (electrodes and vacuumfeedthroughs) is under way, and selection and purchaseof the power supply are the next steps. The nucleationdensity achieved with the current process (seed layer) issufficient to produce continuous (pin-hole free) diamondfilms with a thickness below 100 nm. Implementation ofbias-enhanced nucleation is desired mostly for thecapability of producing highly textured diamond films.Such films are smoother than conventional polycrystallinefilms. Phases II and III are also progressing at theplanned rate. The development of techniques forpreparing molds on silicon wafers has been successful.The shift from using conventional silicon to silicon-on-insulator has allowed greater reproducibility in mold andcantilever fabrication. Pyramid molds are currently beingfabricated and used to test the diamond depositionprocess. Concurrently, the scanning-probe instrumentthat will be used for the evaluation of these nanotools hasbeen installed in LBNL, and final software development isunder way to allow the project to begin collecting data ontool performance and wear.

Keywords: Semiconductor Processing, DeepUltraviolet Lithography, Silicon ProcessingTechnology, Micromachining, ChemicalVapor Deposition, Silicon Wafers,Nucleation Density, Pyramid Molds

261. DEVELOPMENT OF A HIGH-EFFICIENCYROTARY MAGNETOCALORIC REFRIGERATORPROTOTYPE (AL 99 02)$125,000DOE Contact: Samuel J. Barish (301) 903-2917AL Contact: K. A. Gschneidner, Jr. (515) 294-7931

Magnetic refrigeration is based on the magnetocaloriceffect—the ability of some materials to heat up whenmagnetized and cool when removed from the magneticfield. Using these materials as refrigerants would providean environmentally friendly alternative to the volatile liquidchemicals, such as chlorofluorocarbons andhydrochlorofluorocarbons, used in traditional vapor-cyclecooling systeThe new materials have two advantagesover existing magnetic coolants: they exhibit a giantmagnetocaloric effect, and their operating temperature

can be tuned from about 30K (-400/F) to about 290K(65/F) by adjusting the ratio of silicon togermanium—the more germanium, the lower thetemperature. The efficiency of the new materials makemagnetic refrigeration even more competitive withconventional gas-compression technology by replacingcomplex and costly superconducting magnets withpermanent magnets in refrigerator designs. Theelimination of superconducting magnets may also openthe way for small-scale applications of this technology,such as climate control in cars and homes, and in homerefrigerators and freezers. In addition, G. Schneidnersays, “the discovery may also launch totally newapplications for efficient refrigerators at very lowrefrigeration powers since gas compression technologycannot be scaled down to such low cooling powers andsince thermoelectric cooling is very inefficient (30 timesless than magnetic refrigerants).” The first gadolinium-based magnetic refrigerator has been demonstrated.The refrigerator has been operating for over six months,which far exceeds the few hours or days of operationrecorded by similar units. In addition, the unit hasachieved cooling power 20 to 1,000 times greater thanprevious units. Currently, the team is working to findpractical means of processing the new materials toconstruct and test a variety of magnetic refrigerators,which span temperatures from 20K (-425/F) to 300K(80/F) and have cooling powers ranging from one watt to50,000 watts. The project transfers DOE’s investmentsin materials research to research in energy efficiencythrough reduction in operating costs in air conditioningand refrigeration. Keywords: Magnetocaloric Effect, Magnetocaloric

Refrigeration, Gadolinium-Based MagneticMaterials

262. DIRECT CASTING OF TITANIUM ALLOY WIREFOR LOW-COST AEROSPACE ANDAUTOMOTIVE FASTENERS (PNL 99 02)$73,000DOE Contact: Samuel J. Barish (301) 903-2917PNNL Contact: Mark Smith (509) 376-2847

Current wire production methods require large ingots toundergo multiple reduction steps until a diameter of7mm or less is obtained. The reduction steps are energyintensive, require expensive equipment, and result in thegeneration of scrap materials and undesirable etchantand lubricant waste. Economic analysis indicates thatdirect casting of a titanium wire to a diameter slightlylarger than the desired final product, followed byrelatively small final reduction steps, will result insignificant savings to the aerospace industry and othertitanium wire/rod users.

The direct casting process involves the use of a titaniumcore wire to serve as the carrier substrate onto which

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titanium will be cast and solidified at high feed rates. Theobjectives of the project include the development ofunique atmosphere-controlled casting equipment, theapplication of thermal models to optimize the design andoperation of the casting process, and extensive materialstesting and characterization to establish the capability ofthe process to match properties produced byconventional processing. The project extends DOEinvestments in materials characterization to developprocess technologies which further reduction of industrialwaste emissions.

Keywords: Titanium Alloy Wire, Casting Processes

263. NONCONSUMABLE METAL ANODES FORPRIMARY MAGNESIUM PRODUCTION(ANL 98 05)$110,000DOE Contact: Samuel J. Barish (301) 903-2917ANL Contact: Michael J. Pellin (630) 252-3510

This project will develop a nonconsumable metal anodeto replace consumable carbon anodes now used incommercial electrolysis cells for primary magnesiumproduction. The use and manufacture of consumablecarbon anodes, which must be constantly replaced, iscostly, energy consuming, and occasions unwantedgaseous emissions such as CO2 and HCl. In support ofthe DOE mission for energy efficient, environmentallysound industrial processes, ANL has identified certainmetal alloys that are promising candidate materials fornonconsumable anodes. Such alloys form self-limitingsurface oxide films that are thin enough to allow currentto pass, yet thick enough to prevent attack of theunderlying metal. These alloys are dynamic in that themore volatile, reactive components segregate to thesurface at rates sufficient to reform the protective film asit dissolves in the chloride melt. The project will formsurface films on candidate alloys and investigate themusing surface analysis instruments and techniques.Promising alloys will be tested as anodes in bench-scalemagnesium electrolysis cells. Cell operation will bemonitored and interrupted at key points to remove theanode and investigate its surface film. If desirable, theanode film thickness and strain during electrolysis inspecially designed cells will be studied. Alloys identifiedas optimal will be subject to long-term bench-scale testsby Dow Chemical Company, and then tested in full-scalecells at Dow’s production facility in Freeport, Texas.Successful completion of this work will result in increasedU.S. competitiveness and lower magnesium prices whichwould, for example, allow magnesium to be used morewidely in the transportation sector, resulting in lowercosts there. If successful, stable anodes would reducethe operation cost of making magnesium by 20-30 percent and eliminate the emission of CO2 and otherhalocarbon gases during magnesium production byeliminating the need for carbon anodes, now used to

produce magnesium electrolytically. Moreover, this workwill illuminate the mechanisms associated with filmformation on alloys. An understanding of thesemechanisms (e.g., surface segregation, near surfacediffusion) will provide the basis for developing a newclass of corrosion resistant materials that can findapplication in harsh chemical environments, for exampleas nonconsumable anodes for aluminum production.

Keywords: Magnesium Production, Metal Anodes,Metal Alloy, CO2 Emissions, CorrosionResistant, Film Formation

264. OPTIMIZED CATALYSTS FOR THE CRACKINGOF HEAVIER PETROLEUM FEEDSTOCKS(LBNL 99 01)$67,000 DOE Contact: Samuel J. Barish (301) 903-2927LBL Contact: Gabor Somorjai (510) 486-4831

Catalysts lower the energy required for chemicalreactions to proceed and are widely used in petroleumrefining and chemical manufacturing. The useful lifetimeand, thus, the value of an industrial catalyst are limitedby a process known as deactivation in which theefficiency of the catalyst declines over time.Understanding the deactivation process is essential fordeveloping new catalysts with longer useful lifetimes.There are two industrially important catalytic systemsunder study at present. In the first study, zeolite-basedcatalysts are being developed to remove undesiredsulfur compounds from gasoline. The goal of this projectis to evaluate the mechanism by which sulfur isadsorbed on the catalyst. Of particular interest is theidentification of catalyst “active sites” that actuallyinteract with the sulfur. This is done by spectroscopicallymonitoring the identity of the surface species underreaction conditions. The second system under study isthe “reforming” reactions of n-hexane and n-heptanewith hydrogen that produce high octane gasoline byconverting the reactants to benzene and toluene.Deactivation in these catalysts proceeds via “coking,”the buildup and polymerization of carbonaceous reactionbyproducts on the surface of the catalyst. The vibrationalspectra of these byproducts will be obtained by UV-Raman spectroscopy for identification purposes.Ultraviolet excitation is required in this case to avoidinterference from black body radiation from the hotcatalyst material. Identification of problematic surfacespecies will allow determination of the precisemechanism by which deactivation occurs in this system.These improvements will have a major impact on theefficiency of petroleum refining and gasoline production.The new surface science tools under development willhave applicability to general studies in catalysis and

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surface science and support the DOE’s mission in designand characterization of advanced materials.

Keywords: In-Situ Surface UV-Raman Spectroscopy,Catalytic Surfaces, Catalyst Deactivation,Zeolite Based Materials

SMALL BUSINESS INNOVATION RESEARCHPROGRAM


PHASE I

Silicon Carbide High Temperature Dynamic PressureGauge - DOE contact Richard J. Dunst, (412) 386-6694;Busek Company, Inc. contact Judy Budny,(508) 655-5565

Turbine Blade Emissivity Sensor - DOE contact CharlesT. Alsup, (304) 284-5432; En'urga, Inc. contact VinooNarayan, (765) 497-3269

Development of Robust NOx Monitor - DOE contactRichard J. Dunst, (412) 386-6694; Nextech Materials,Ltd. contact William J. Dawson, (614) 842-6606

Amorphous, Non-Oxide Seals, Derived from OrganicPrecursors, for Solid Oxide Fuel Cells - DOE contactLane Wilson, (304) 285-1336; Ceramatec, Inc. contactDr. Michael A. Keene, (801) 978-2152

Perovskite/Oxide Composites as Mixed Protonic/Electronic Conductors for Hydrogen Recovery in IGCCSystems - DOE contact Arun C. Bose, (412) 386-4467;Ceramatec, Inc. contact Dr. Michael Keene,(801) 978-2152

Highly Textured Composite Seals for SOFCApplications - DOE contact Lane Wilson,(304) 285-1336; Nextech Materials, Ltd. contactWilliam J. Dawson, (614) 842-6606

Internal Pipe Repair System - DOE contact MagdaRivera, (304) 285-1359; Foster-miller, Inc. contactMr. Ross R. Olander, (781) 684-4242

Assure Natural Gas and Oil Pipeline Reliability byCost-Effective, High-Performance Thermoplastic Liners -DOE contact Magda Rivera, (304) 285-1359; FrontierPerformance Polymers Corporation contact Dr. Jerry S.Chung, (973) 331-0923

Biomimetic Membrane for Carbon Dioxide Capture fromFlue Gas - DOE contact Frank Ferrell, (301) 903-3768;Carbozyme, Inc. contact Dr. Michael C. Trachtenberg,(609) 499-3600

Catalysts and Membrane for Selective MethaneOxidative Dimerization - DOE contact Charles Taylor,(412) 386-6058; Eltron Research, Inc. contactMs. Eileen E. Sammells, (303) 530-0263

High Efficiency Amorphous and MicrocrystallineSilicon Based Double-Junction Solar Cells Made withVery-High-Frequency Glow Discharge - DOE contactSatyen Deb, (303) 384-6405; United Solar SystemsCorp. contact J. Vanaharam, (248) 364-5611

Low-Cost Nanoporous Sol Gel Separators for Lithium-Based Batteries - DOE contact Jim Barnes,(202) 586-5657; Optodot Corporation contactDr. Steven A. Carlson, (617) 494-9011

The Development of a Low-Cost Separator withImproved Performance - DOE contact Jim Barnes,(202) 586-5657; Yardney Technical Products, Inc.contact Vincent Yevoli, (860) 599-1100

New Solid State Lighting Materials - DOE contact JamesBrodrick, (202) 586-1856; Maxdem, Inc. contact LindaHope, (909) 394-0644

Monomer-Excimer Phosphorescent White OLEDS forGeneral Lighting - DOE contact James Brodrick,(202) 586-1856; Universal Display Corporation contactJanice K. Mahon, (609) 671-0980

White Illumination Sources Using StripedPhosphorescent OLEDs - DOE contact James Brodrick,(202) 586-1856; Universal Display Corporation contactJanice K. Mahon, (609) 671-0980

An Approach for Reducing Wind Turbine Tower Weightby 70 Percent by Combining an Innovative On-SiteManufacturing Method with a Novel Tower Design -DOE contact John Cadogan, (202) 586-1991;Composite Support & Solutions, Inc. contact Dr.Clement Hiel, (310) 265-0850

Development of a Low Wind Turbine Blade MakingOptimal Use of Carbon Fiber Composites - DOE contactJohn Cadogan, (202) 586-1991; Global EnergyConcepts, Llc contact Robert Poore, (425) 822-9008

Utilization of Isotruss Technology in Taller Wind TurbineTowers - DOE contact John Cadogan, (202) 586-1991;Wasatch Valley Technologies, Llc contact ChristopherDerrington, (801) 264-5600

Transformer Ratio Enhancement Experiment for NextGeneration Dielectric Wakefield Accelerators - DOEcontact Jerry Peters, (301) 903-3233; Euclid ConceptsLlc contact Dr. A.D. Kanereykin, (440) 519-0410

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Inexpensive High Quality Electron Sources - DOE contactJerry Peters, (301) 903-3233; Genvac Aerospace contactCarole Ream, (440) 646-9986

Continuous Formation of Ta Barrier and Cu Sheath ofNb3Sn Subelements - DOE contact Jerry Peters,(301) 903-3233; Accelerator Technology Corporationcontact Dr. Peter McIntyre, (979) 255-5531

Concentric Tilted Double-Helix Dipole Magnets - DOEcontact Jerry Peters, (301) 903-3233; Advanced MagnetLaboratory, Inc. contact Mark Senti, (321) 728-7543

Multifilament Extrusion Cuprate Superconductors - DOEcontact Jerry Peters, (301) 903-3233; Alchemet, Inc.contact Katherine L. Miller, (610) 566-5964

Advanced, High-Filament-Count, Nb3Al, Jelly-Roll Strandfor Accelerator Applications - DOE contact Jerry Peters,(301) 903-3233; Hyper Tech Research Inc. contactMichael Tomsic, (937) 332-0348

Eliminating a Major Cause of Wire Drawing Breakage inA-15 High-Field Superconductors - DOE contactJerry Peters, (301) 903-3233; Innovare, Inc. contactDr. Alfred R. Austen, (610) 837-8830

Optimization and Commercialization of the Cable-In-TubeApproach to Fabricating High Performance Nb3Sn Wires -DOE contact Jerry Peters, (301) 903-3233;Superconducting Systems, Inc. contact Dr. ShanhinPourrahimi, (781) 642-6702

High Current Density (Jc), Low AC Loss, Low CostInternal-Tin Superconductors - DOE contact Jerry Peters,(301) 903-3233; Supergenics contact Bruce Zeitlin,(941) 349-0930

Hybrid Electrochemical - Electrolytic Capacitor forNext-Generation Electron-Positron Linear Collider -DOE contact Jerry Peters, (301) 903-3233; GinerElectrochemical Systems, LLC contact Dr. Anthony J.Vaccaro, (781) 529-0504

Microwave Component Fabrication using the FastCombustion Driven Compaction Process - DOE contactJerry Peters, (301) 903-3233; Utron, Inc. contactDr. F. Douglas Witherspoon, (703) 369-5552

A High Thermal Performance, Self-Contained HeatExtraction System suited to Highly Distributed HeatSources, with Premise Based on Ultra-LightweightConsiderations - DOE contact Michael P. Procario,(301) 903-2890; Allcomp, Inc. contact Wei Shih,(626) 369-4572

Cylindrical Electrode-Less Gas Electron Multiplier - DOEcontact Michael P. Procario, (301)903-2890; Ion Optics,Inc. contact James C. Louney, (781) 788-8777

Micro-Photomultiplier Array - DOE contact JehanneSimon-Gillo, (301) 903-1455; Nanosciences Corporationcontact Dr. Charles Beetz, (203) 267-4440

Electrically Medicated Microetching ManufacturingProcess to Replace Emersion and Spray Etching - DOEcontact Jehanne Simon-Gillo, (301) 903-1455; FaradayTechnology, Inc. contact Dr. E. Jennings Taylor,(937) 836-7749

Radiation Hard Lead Zirconium Titanium (PZT) forFerroelectric and Plezoelectric Devices - DOE contactJehanne Simon-Gillo, (301) 903-1455; StructuredMaterials Industries, Inc. contact Joseph D. Cuchiaro,(719) 260-9589

Innovative Helium-Cooled Tungsten PFCs - DOEcontact Sam E. Berk, (301) 903-4171; PlasmaProcesses, Inc. contact Timothy McKechnie,(256) 851-7653

Insulators and Materials for Close-SpacedThermoelectric Modules - DOE contact Robert Wiley,(301) 903-2884; Hi-z Technology, Inc. contact Norbert B.Elsner, (858) 695-6660

Separation and Enrichment of Xenon in Air - DOEcontact Ken Quitoriano, (925) 423-6331; MembraneTechnology And Research, Inc. (MTR) contact ElizabethWeiss, (650) 328-2228

A Small Seismic Accelerometer Utilizing Single CrystalPiezoelectric Material - DOE contact Ken Quitoriano,(925) 423-6331; Wilcoxon Research, Inc. contact DavidL. Spilis, (301) 216-3016

High Performance Thermo-Electrically-Cooled LWIRMercury Cadmium Telluride Detectors - DOE contactKen Quitoriano, (925) 423-6331; Fermionics Corporationcontact Dr. C. C. Wang, (805) 582-0155

Nano Liter Scale Blood Sampling and Analysis System -DOE contact Dean Cole, (301) 903-3268; PhoenixBioscience contact Kumar Subramanian,(925) 858-0484

VEGF-Based Delivery of Boron Therapeutics - DOEcontact Peter Kirchner, (301) 903-9106; Sibtech, Inc.contact Dr. Joseph M. Backer, (860) 953-1164

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PHASE II (FIRST YEAR)

A High-Power, Ceramic, RF Generator and Extractor -DOE contact Jerry Peters, (301) 903-3233; DulyResearch, Inc. contact Dr. David U. L. Yu,(310) 548-7123

KA-Band RF Transmission Line Components for aHigh-Gradient Linear Accelerator - DOE contactJerry Peters, (301) 903-3233; Omega-p, Inc. contactGeorge P. Trahan, (203) 458-1144

A Method to Increase Current Density in a Mono ElementInternal Tin Process Superconductor Utilizing ZrO2 toRefine the Grain Size - DOE contact Jerry Peters,(301) 903-3233; Supergenics contact Bruce Zeitlin,(941) 349-0930

Hermetic Metallization of Aluminum Nitride for RadioFrequency Devices - DOE contact Jehanne Simon-Gillo,(301) 903-1455; Sienna Technologies, Inc. contactDr. Canan Savrun, (425) 485-7272

A Liquid-Desiccant Heating/Cooling System Poweredby Solar Energy - DOE contact Lew Pratsch,(202) 586-1512; Ail Research, Inc. contactDr. Andrew Lowenstein, (609) 452-2950

Truss-Integrated Thermoformed Ductwork - DOEcontact Esher Kweller, (202) 586-9136; Steven WinterAssociates, Inc. contact Marie Starnes, (203) 857-0200

Novel Membrane Reactor for the Desulfurization ofTransportation Fuels - DOE contact CharlieRussomanno, (202) 586-7543; Trans Ionics Corporationcontact Sandra C. Schucker, (281) 296-9210

Low Emission Diesel Engines - DOE contact CharlieRussomanno, (202) 586-7543; Compact MembraneSystems, Inc. contact Nadine Cragg-Lester,(302) 999-7996

Low-Cost, Large-Membrane-Area Modules for GasSeparation - DOE contact Charlie Russomanno,(202) 586-7543; Membrane Technology And Research,Inc. (MTR) contact E. G. Weiss, (650) 328-2228

Novel Nano-Structured Catalyst for Steam Gasification ofCarbonaceous Feedstocks - DOE contact Doug Archer,(301) 903-9443; Ceramem Corporation contactDr. Robert L. Goldsmith, (781) 899-4495

Amended Silicate Sorbents for Mercury Removal fromFlue Gas - DOE contact Barbara Carney,(304) 285-4671; ADA Technologies, Inc. contactClifton H. Brown, (303) 792-5615

Control of Catalyst Poisons from Coal Gasifiers - DOEcontact Bob Kornosky, (412) 386-4521; TDA Research,Inc. contact Michael Karpuk, (303) 940-2301

High-Temperature Highly-Efficient Ceramic HeatExchanger - DOE contact Richard J. Dunst,(412) 386-6694; Ceramatec, Inc. contact Dale M. Taylor,(801) 978-2132


PHASE II (SECOND YEAR)

Non-Linear Optical Devices for High PerformanceNetworking, Computing and Telecommunication Routingand Modulating - DOE contact George Seweryniak,(301) 903-0071; Ionic Systems, Inc. contact ConstanceEve Teague, (408) 885-0800

Advanced Geothermal Optical Transducer (AGOT) -DOE contact Raymond J. LaSala, (202) 586-4198; LELCorporation contact Piedao H. Liucci, (201) 569-8641

Fast-Response, Two-Dimensional Detector forEpithermal Neutron Detection with Adjustable Shape -DOE contact Helen Kerch, (301) 903-2346; NovaScientific, Inc. contact Dr. Paul L. White, (508) 347-7679

Ceramic Appliques for the Production of SupportedThin-Film Catalytic Membrane Reactors - DOE contactCharlie Russomanno, (202) 586-7543; Eltron Research,Inc. contact Eileen E. Sammells, (303) 530-0263

Affinity Ceramic Membranes with Carbon DioxideTransport Channel - DOE contact Charlie Russomanno,(202) 586-7543; Media and Process Technology, Inc.contact Dr. Paul K.T. Liu, (412) 826-3721

Photocatalytic Membranes for Producing UltrapureWater - DOE contact Charlie Russomanno,(202) 586-7543; Technology Assessment & Transfer,Inc. contact Sharon S. Fehrenbacher, (410) 224-3710

Novel Membrane Reactor for Fischer-TropschSynthesis - DOE contact Charlie Russomanno,(202) 586-7543; CeraMem Corporation contactDr. Robert Goldsmith, (781) 899-4495

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Fast, Low-Noise Readout Chip for AvalanchePhotodiode Arrays for Use in Positron-EmissionTomography Imaging - DOE contact Prem Srivastava,(301) 903-4071; Nova R & D, Inc. contactRaymond B. Pifer, (909) 781-7332

Miniature Electrochemical Carbon Dioxide Detector -DOE contact Roger Dahlman, (301) 903-4951; SuperiorSensing Solutions contact Michael J. Newman,(303) 702-1672

An Innovative Ultramicroelectrode Array forField-Deployable Trace Metal Analysis - DOE contactPaul Bayer, (301) 903-5324; Lynntech, Inc. contactDr. G. Duncan Hitchens, (979) 693-0017

Novel Joining Technique for Oxide-DispersionStrengthened Iron Aluminide Alloys - DOE contactRichard Read, (412) 386-5721; Materials &Electrochemical Research (MER) Corp. contactDr. R. O. Loutfy, (520) 574-1980

A Metallic Interconnect for Intermediate Temperature,Planar, Solid Oxide Fuel Cells - DOE contactWayne Surdoval, (412) 386-6002; Materials andSystems Research, Inc. contact Dr. Dinesh K. Shetty,(801) 530-4987

Tailorable, Inexpensive Carbon Foam Electrodesfor High-Efficiency Fuel Cell and ElectrochemicalApplications - DOE contact Richard Read,(412) 386-5721; Touchstone Research Laboratory, Ltd.contact Brian E. Joseph, (304) 547-5800

Advanced Cathode Structure for Oxygen Reduction inPolymer Electrolyte Membrane Fuel Cells - DOE contactRonald J. Fiskum, (202) 586-9154; FuelCell Energy, Inc.contact Dr. Hans Maru, (203) 825-6006

Efficient Incandescent Lighting Based on SelectiveThermal Emitters - DOE contact John Ryan,(202) 586-9130; Foster-Miller, Inc. contact Adi R. Guzdar,(781) 684-4239

'On Chip' Smart Sensor Array and Control Teleplatformfor Thermophotovoltaic Cell Manufacturing Applications -DOE contact Alec Bulawka, (202) 586-5633; ARSECOcontact Marine Boyadzhyan, (818) 249-6362

Infrared Focal Plane Array with Fast Shuttering - DOEcontact Eric Sander, (202) 586-5852; Princeton ScientificInstruments, Inc. contact John L. Lowrance,(732) 274-0774

Linear Avalanche Photodiode Detector Arrays for GatedSpectroscopy with Single-Photon Sensitivity - DOEcontact Eric Sander, (202) 586-5852; RadiationMonitoring Devices, Inc. contact Dr. Gerald Entine,(617) 926-1167

Development of a Large-Area Mercuric IodidePhotodetector for Scintillation Spectroscopy - DOEcontact Jehanne Simon-Gillo, (301) 903-1455;Constellation Technology Corporation contactCharles Settgast, (727) 547-0600

Segmented, Deep-Sensitive-Depth Silicon RadiationDetectors - DOE contact Jehanne Simon-Gillo,(301) 903-1455; IntraSpec, Inc. contact John Walter,(865) 483-1394

Micromachined Silicon, Large Area X-ray Detector -DOE contact Jehanne Simon-Gillo, (301) 903-1455;Physical Optics Corporation contact Gordon Drew,(310) 320-3088

Cost Reduction Techniques for Powder-in-TubeNiobium-Tin Superconductors - DOE contact JerryPeters, (301) 903-5228; Supercon, Inc. contact ElaineTarkiainen, (508) 842-0174

Flexible Niobium-Tin Cables Suitable toReact-then-Wind Approach to Fabricating AcceleratorMagnets - DOE contact Jerry Peters, (301) 903-5228;Superconducting Systems, Inc. contact Dr. ShaninPourrahimi, (781) 642-6702

Novel Avalanche Photodiode Arrays for ScintillatingFiber Readout - DOE contact Michael P. Procario,(301) 903-2890; Radiation Monitoring Devices, Inc.contact Dr. Gerald Entine, (617) 926-1167

Manufacturing of Robust Ceramic/Metal Joints for AlkaliMetal Thermal-to-Electric Converters - DOE contactLisa C. Herrera, (301) 903-8218; Triton Systems, Inc.contact Ross Haghighat, (978) 250-4200


PHASE I

Multilayer Composite Membranes for UpgradingAcid-Rich Natural Gas - DOE contact Tony Zammerilli,(304) 285-4641; Membrane Technology And Research,Inc. (MTR) contact Elizabeth Weiss, (650) 328-2228

Low-Temperature, Solid Oxide Fuel Cell CathodeDevelopment - DOE contact Lane Wilson,(304) 285-1336; Ceramatec, Inc. contactDr. Michael Keene, (801) 978-2152

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Use of Graphite Nanofibers as a Catalyst for theSynthesis of Styrene - DOE contact CharlieRussomanno, (202) 586-7543; Catalytic Materials, Ltd.contact Dr. Nelly Rodriguez, (508) 893-9561

Modeling of Copper-Indium-Gallium Diselenide forAdvanced Thin-Film Photovoltaic Devices - DOE contactSatyen Deb, (303) 384-6405; Helio Volt Corporationcontact Dr. Ronald P. Gale, (617) 962-2608

Stabilized Lithium Manganese Oxide Spinel Cathode forHigh Power Li-Ion Batteries - DOE contact Jim Barnes,(202) 586-5657; Farasis Energy, Inc. contactDr. Keith D. Kepler, (650) 594-4380

A Multi-Megawatt Continuous Wave RF Window forParticle Accelerator Applications - DOE contact JehanneSimon-Gillo, (301) 903-1455; Tunnel Dust, Inc. contactRoisin F. Preble, (757) 898-3373

An IR Imaging and Spectral Diagnostic System forAlcator C-Mod - DOE contact Charles Finfgeld,(301) 903-3423; Science Research Laboratory, Inc.contact Dr. Jonah Jacob, (617) 547-1122

A Solid-State Irradiance Calibrator for Field Use - DOEcontact Michael Huesemann, (360) 681-3618; YankeeEnvironmental Systems, Inc. contact Cynthia A. Cote,(413) 863-0200



Doppler Laser Radar for Non-Intrusive Liquid MetalFlow Characterization - DOE contact Sam E. Berk,(301) 903-4171; Think Tank, Inc. contact Dr. MadhavanM. Menon, (865) 966-6200

Multi-Megawatt Circulator for TE01 Waveguide - DOEcontact Jerry Peters, (301) 903-3233; Calabazas CreekResearch contact Dr. Lawrence Ives, (408) 741-8680

Active Vibration Control of NLC Magnets - DOE contactJerry Peters, (301) 903-3233; Energen, Inc. contactDr. Chad H. Joshi, (978) 671-5400

An Electrical Condition Monitoring Approach for Wire andCable - DOE contact Frank Ross, (301) 903-4416; BPWIncorporated contact Shelby J. Morris Jr., (757) 850-8679

X-ray Diagnostics for High-Temperature SuperconductorProcessing - DOE contact David Welch, (631) 344-3517;Aracor contact Ed LeBaker, (408) 733-7780

Non-Invasive Techniques to Study Local PassivityBreakdown of Metal Alloys in Aqueous Media - DOEcontact Kevin Zavadil, (505) 845-8442; ApplicableElectronics, Inc. contact Alan M. Shipley,(508) 833-5042

Microelectrode Array for Electrochemical Sensing ofLocalized Corrosion - DOE contact Kevin Zavadil,(505) 845-8442; Faraday Technology, Inc. contactDr. E. Jennings Taylor, (937) 836-7749

Intelligent Probes for Enhanced Non-DestructiveDetermination of Degradation in Hot-Gas-PathComponents - DOE contact Lane Wilson,(304) 285-1336; Jentek Sensors, Inc. contactDr. Neil J. Goldfine, (781) 642-9666



Utilization of Hydrocarbon Fuels in Low-TemperatureSolid Oxide Fuel Cells - DOE contact Wayne Surdoval,(412) 386-6002; Applied Thin Films, Inc. contact DerrickCalandra, (847) 467-6877

Thin Alternatives to Braided Glass Insulation forLow-Temperature Superconducting Wire - DOE contactJerry Peters, (301) 903-5228; MicrocoatingTechnologies contact Jeffrey Moore, (678) 287-2400


PHASE I

Embedded Sensors in Turbine Systems by DirectWrite Thermal Spray Technology - DOE contactCharles T. Alsup, (304) 284-5432; MesoscribeTechnologies, Inc. contact Richard Gambino,(631) 632-9513

Contamination Resistant Anodes for IntermediateTemperature Solid Oxide Fuel Cells - DOE contactLane Wilson, (304) 285-1336; Eltron Research, Inc.contact Eileen E. Sammells, (303) 530-0263

CU-SDC Nanostructural Electrodes as Coking-ResistantAnodes for Intermediate-Temperature SOFCS - DOEcontact Lane Wilson, (304) 285-1336; MicrocoatingTechnologies contact David L. Motley, (678) 287-2445

Low-Cost Protective Layer Coatings on Thermal BarrierCoatings via CCVD - DOE contact Udaya Rao,(412) 386-4743; Microcoating Technologies contactDavid L. Motley, (678) 287-2445

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A Commercially Viable Carbon Molecular SieveMembrane for Subquality Natural Gas - DOE contactTony Zammerilli, (304) 285-4641; Media And ProcessTechnology, Inc. contact Dr. Paul KT Liu, (412) 826-3721

Catalyst to Improve Small-Scale Claus Plants - DOEcontact Tony Zammerilli, (304) 285-4641; Tda Research,Inc. contact John D. Wright, (303) 940-2300

LSGM Based Composite Cathodes for Anode Supported,Intermediate Temperature (600-800 degrees C) SolidOxide Fuel Cells (SOFC) - DOE contact Lane Wilson,(304) 285-1336; Materials And Systems Research, Inc.contact Dr. Dinesh K. Shetty, (801) 530-4987

Advanced Structural Carbon-Supported Catalysts forIndustrial Polymer Synthesis - DOE contact CharlieRussomanno, (202) 586-7543; Environmental And LifeSupport Technologies, Inc. contact Clifford D. Jolly,(303) 840-4221

Metal Oxide Catalyst for Methacrylic Acid Preparation viaOne-Step Oxidation of Isobutane - DOE contact CharlieRussomanno, (202) 586-7543; Evernu Technology, LLCcontact Dr. Manhua Mandy Lin Ph.D, (215) 649-8574

Solid-Acid Catalyst for Refinery Alkylation - DOE contactCharlie Russomanno, (202) 586-7543; Exelus, Inc.contact Mitrajit Mukherjee, (973) 740-2350

Structured Catalyst for Exothermic Reactions - DOEcontact Charlie Russomanno, (202) 586-7543; Exelus,Inc. contact Mitrajit Mukherjee, (973) 740-2350

Development of Ion Beam Techniques for LayerSplitting of Oxide Materials - DOE contact Tony Haynes,(865) 576-2858; Ues, Inc. contact Francis F. Williams, Jr.,(937) 426-6900

A Novel Technique to Produce Ultra-Porous MetallicFoams through Thermal Reduction of Nano-ParticleOxide - DOE contact Mike Kassner, (541) 737-7023;Micropyretics Heaters International, Inc. contactDr. A. Vissa, (513) 772-0404

Novel High Temperature Polymer Substrate for Low CostHigh Efficiency Thin Film CIGS Solar Cells - DOE contactSatyen Deb, (303) 384-6405; Foster-miller, Inc. contactRoss R. Olander, (781) 684-4242

Non-Vacuum Techniques for Front and Back contactsfor CIGS Solar Cells - DOE contact Satyen Deb,(303) 384-6405; International Solar Electric Technology,Inc. contact Dr. Vijay K. Kapur, (310) 216-1423

Transparent Conducting Oxide Films with HighRefractive Index - DOE contact Satyen Deb,(303) 384-6405; Microcoating Technologies contactDavid L. Motley, (678) 287-2445

P-Type ZnO Films - DOE contact Satyen Deb,(303) 384-6405; Structured Materials Industries, Inc.contact Dr. Gary S. Tompa, (732) 885-5909

An Advanced Cathode Material for Li-Ion Battteries -DOE contact Jim Barnes, (202) 586-5657; A123Systems contact Mr.Ric Fulop, (617) 250-0565

Polymer and Gel Electrolyte for Lithium Sulfur Batteries -DOE contact Jim Barnes, (202) 586-5657; MoltechCorporation contact Dr.Jim Akridge, (520) 799-7516

The Development of a Polyvalent Battery System - DOEcontact Jim Barnes, (202) 586-5657; Yardney TechnicalProducts, Inc. contact Vince Yevoli, (860) 599-1100

Synthesis & Integration of Quantum Confined Atom(QCA) Nanophosphor Based Down Converter forAlInGaN-Based High Luminous Efficiency White-LightLED Lamps - DOE contact Eric Jones, (505) 844-8752;Nanocrystals Technology, Ltd. contact Dr. RameshwarN. Bhargava, (914) 923-1142

General Illumination Using Dye-Doped Polymer LightEmitting Devices - DOE contact James Brodrick,(202) 586-1856; Intelligent Optical Systems, Inc. contactDr. Ashutosh Sharma, (310) 530-7130

Nanomaterials-Based Electrodes for High Charge RateEnergy Storage Devices of HEVs - DOE contact ImreGyuk, (202) 586-1482; Nanopowder Enterprises, Inc.contact Dr. Gary S. Tompa, (732) 885-5909

Supported Urania Catalysts for Fatty Acid MethylEster Dehydrogenation - DOE contact Amy Miranda,(202) 586-6471; Ceramem Corporation contactDr. Richard Higgins, (781) 899-4495

Three-Dimension Woven Carbon-Glass Hybrid WindTurbine Blades - DOE contact John Cadogan,(202) 586-1991; 3tex, Inc. contact R. Bradley Lienhart,(919) 481-2500

PIT Nb3Sn Superconducting Strands Based on aModified Powder/Tube Reaction Route - DOE contactJerry Peters, (301) 903-3233; Hyper Tech Research Inc.contact Michael Tomsic, (937) 332-0348

Non-Copper Jc of 2800 A/mm2 through Optimization ofPIT Nb3Sn Conductor Design - DOE contact JerryPeters, (301) 903-3233; Supercon, Inc. contact TerenceWong, (508) 842-0174

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An Elemental Powder Approach for High PerformanceNb3Sn Superconductors - DOE contact Jerry Peters,(301) 903-3233; Supercon, Inc. contact Terence Wong,(508) 842-0174

Feasibility of Cost Effective, Long Length, BSCCO 2212Round Wires, for Very High Field Magnets, Beyond 12Tesla at 4.2 Kelvin - DOE contact Jerry Peters,(301) 903-3233; Superconductive Components, Inc.contact J.R. Gaines, Jr., (614) 486-0261

A New Method for Depositing Niobium Films forNiobium/Copper Cavities - DOE contact JehanneSimon-Gillo, (301) 903-1455; Tunnel Dust, Inc. contactRoisin F. Preble, (757) 898-3373

Growth of a New, Fast Scintillator Crystal for NuclearExperiments - DOE contact Jehanne Simon-Gillo,(301) 903-1455; Ceramare Corporation contactDr. Larry E. McCandlish, (732) 937-8260

A Superior Scintillator Material for High ResolutionX-ray Detectors - DOE contact Jehanne Simon-Gillo,(301) 903-1455; Nanomat, Inc. contact Shree Kumar,(724) 861-6125

A New Scintillator for Gamma Ray Spectroscopy - DOEcontact Jehanne Simon-Gillo, (301) 903-1455; RadiationMonitoring Devices, Inc. contact Dr. Gerald Entine,(617) 926-1167

Diamond Windows for High Power MicrowaveTransmission - DOE contact T. V. George,(301) 903-4957; Coating Technology Solutions, Inc.contact Dr. Roy Gat, (617) 625-2725

Radiation Resistant Insulation with Improved ShearStrength for Fusion Magnets - DOE contact WarrenMarton, (301) 903-4958; Composite TechnologyDevelopment, Inc. contact Dr. Naseem A. Munshi,(303) 664-0394

Nanostructured Tungsten for Improved Plasma FacingComponent Performance - DOE contact Sam E. Berk,(301) 903-4171; Plasma Processes, Inc. contact TimothyMcKechnie, (256) 851-7653

High-Strength, High-Conductivity Composite for PlasmaFacing Applications - DOE contact Sam E. Berk,(301) 903-4171; Supercon, Inc. contact Terence Wong,(508) 842-0174

Rugged Packaging for Damage Resistant InertialFusion Energy Optics - DOE contact Gene Nardella,(301) 903-4956; Pvd Products, Inc. contact Dr. James A.Greer, (978) 694-9455

Low Cost Materials for Neutron Absorption in GenerationIV Nuclear Power Systems - DOE contact MadelineFeltus, (301) 903-2308; Powdermet, Inc. contact AndrewSherman, (818) 768-6420

High Resolution Gamma Ray Spectrometer for NuclearNon-Proliferation - DOE contact Ken Quitoriano,(925) 423-6331; Radiation Monitoring Devices, Inc.contact Dr. Gerald Entine, (617) 926-1167

Growth of a New Mid-IR Laser Crystal - DOE contactKen Quitoriano, (925) 423-6331; Ceramare Corporationcontact Dr. Larry E. McCandlish, (732) 937-8260

Ultrapurification, Crystal Growth, and Characterizationof Rare-Earth Doped KPb2Br5 for Mid-Infared Lasers -DOE contact Ken Quitoriano, (925) 423-6331; EicLaboratories, Inc. contact Dr. R. David Rauh,(781) 769-9450

Induim Arsenide Antimonide Very Long WavelengthPhotodiodes for Near Room Temperature Operation -DOE contact Ken Quitoriano, (925) 423-6331;Svt Associates contact Jane Marks, (952) 934-2100



Innovative Organic and Inorganic High-PressureLaminate Insulation for Fusion and SuperconductingMagnets - DOE contact Warren Marton, (301) 903-4958;Composite Technology Development, Inc. contactDr. Naseem A. Munshi, (303) 664-0394

Inorganic-Organic Hybrid Materials: Diacetylene-Siloxanes as Radiation Resistant Electrical Insulator forPlasma Fusion Confinement Systems - DOE contactWarren Marton, (301) 903-4958; Eltron Research, Inc.contact Eileen E. Sammells, (303) 530-0263

Ultra-Thin Optical Diagnostic Filters for PlasmaWakefield Accelerators - DOE contact Jerry Peters,(301) 903-3233; Luxel Corporation contact DanWittkopp, (360) 378-4137

Enhanced Efficiency Nanowire Photocathode forLarge PMTs - DOE contact Jehanne Simon-Gillo,(301) 903-1455; Nanosciences Corporation contactDr. John Steinbeck, (203) 267-4440

Superinsulation for Ductwork - DOE contact EsherKweller, (202) 586-9136; Aspen Aerogels, Inc. contactDr. Kang P. Lee, (508) 481-5058

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Recycling of Coated Plastics Used in Automotive, ITand Commercial Applications - DOE contact CharlieRussomanno, (202) 586-7543; Metss Corporation contactDr. Kenneth J. Heater, (614) 842-6600

Two-Step Methane Conversion to Alkynes and Dienes -DOE contact Charlie Russomanno, (202) 586-7543;Ceramem Corporation contact Dr. Robert L. Goldsmith,(781) 899-4495

Improved Buffered Substrates for YBCO CoatedConductors - DOE contact David Welch, (631) 344-3517;American Superconductor Corporation contactThomas M. Rosa, (508) 621-4265

Low Cost MesoCarbon Micro Bead Anodes forLithium-Ion Batteries - DOE contact Jim Barnes,(202) 586-5657; Mer Corp (Materials and ElectrochemicalResearch) contact Dr. J. C. Withers, (520) 574-1980

A Novel Cathode Material for High Power LithiumRechargeable Batteries - DOE contact Jim Barnes,(202) 586-5657; T/j Technologies, Inc. contact LeslieAlexander, (734) 213-1637

Development of Low-Cost Salts for Lithium-Ion,Rechargeable Batteries - DOE contact Jim Barnes,(202) 586-5657; Yardney Technical Products, Inc.contact Vince Yevoli, (860) 599-1100

High-Performance Carbon Materials for Ultracapacitors -DOE contact Ben Hsieh, (304) 285-4254; AdvancedFuel Research, Inc. contact Dr. Michael A. Serio,(860) 528-9806

Synthesis of Bulk Amounts of Double-Walled CarbonNanotubes - DOE contact Ben Hsieh, (304) 285-4254;Mer Corp (materials And Electrochemical Research)contact Dr. J. C. Withers, (520) 574-1980

Intermediate Temperature Solid Oxide FuelCell Development - DOE contact Lane Wilson,(304) 285-1336; Ceramatec, Inc. contact Dr. Michael Keene, (801) 978-2152

Novel Ceria-Based Materials for Low-TemperatureSolid Oxide Fuel Cells - DOE contact Lane Wilson,(304) 285-1336; Nextech Materials, Ltd. contactDr. Scott L. Swartz, (614) 842-6606



The Development and Demonstration of ReliableAdherent Metalization of AIN - DOE contact SamuelBarish, (301) 903-2917; MER Corporation contactDr. R.O. Loutfy, (520) 574-1980

Novel Lithium-Ion Conducting Polymer Electrolytes forLithium-Ion Batteries - DOE contact Susan Rogers,(202) 586-8997; Eltron Research, Inc. contact EileenSammells, (303) 530-0263

Synthesis of New Solid Polymer Electrolytes - DOEcontact Susan Rogers, (202) 586-8997; TPL, Inc.contact H.M. Stoller, (505) 342-4412

Membranes for Reverse Organic-Air Separations - DOEcontact Charlie Russomanno, (202) 586-7543; CompactMembrane Systems, Inc. contact Glenn Walker,(937) 252-8969

Hydrogen Recovery Process Using New MembraneMaterials - DOE contact Charlie Russomanno,(202) 586-7543; Membrane Technology and Research,Inc. contact E.G. Weiss, (650) 328-2228

New Boronated Amino Acids for Neutron CaptureTherapy - DOE contact Peter Kirchner, (301) 903-9106;BioNeutrics, Inc. contact Larry Tummel, (865) 675-5627

Low-Cost Arc Process to Produce Single-WalledNano-Tubes Using Coal-Based Starting Materials -DOE contact Neil Rossmeissl, (202) 586-8668; Materials& Electrochemical Research (MER) Corp. contact Dr. J. C. Withers, (520) 574-1980

Novel Catalyst for Carbon Monoxide Removal fromFuel Cell Reformate - DOE contact Ronald J. Fiskum,(202) 586-9154; KSE, Inc. contact Dr. James R. Kittrell,(413) 549-5506

A Fast, High Light Output Scintillator for Gamma Rayand Neutron Detection - DOE contact JehanneSimon-Gillo, (301) 903-1455; Radiation MonitoringDevices, Inc. contact Dr. Gerald Entine, (617) 926-1167

In-Situ Electron Beam Processing for Radio FrequencyCavities - DOE contact Jerry Peters, (301) 903-5228;FM Technologies, Inc. contact Dr. Frederick M. Mako,(703) 961-1051

An Innovative Fabrication Concept for Niobium-TinSuperconducting Wire - DOE contact Jerry Peters,(301) 903-5228; Alabama Cryogenic Engineering, Inc.contact Dr. John B. Hendricks, (256) 536-8629

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High-Performance Niobium-Tin-TantalumSuperconductors Formed by Mechanical Alloying andNear-Net Shape Tube Filling - DOE contact Jerry Peters,(301) 903-5228; EURUS Technologies, Inc. contactJohn Romans, (850) 574-1800


PHASE I

An Inexpensive, Efficient Neutron Monochromator -DOE contact Helen Kerch, (301) 903-2346; AdelphiTechnology, Inc. contact Dr. Charles K. Gary,(650) 328-7337

High Performance Thermal Neutron Detector - DOEcontact Helen Kerch, (301) 903-2346; Lexitek, Inc.contact Dr. Steven M. Ebstein, (781) 431-9604

Neutron and Electron Beam Instrumentation (MSCP1A20-205) - DOE contact Helen Kerch, (301) 903-2346;Materials Sciences Corporation contact Adam T. Rosen,(215) 542-8400

High Gain, Fast Scan, Broad Spectrum, Parallel BeamWavelength Dispersive X-ray Spectrometer for SEM -DOE contact Dean Miller, (630) 252-4108; ParallaxResearch, Inc. contact David Ohara, (850) 580-5481

Advanced X-ray Detectors for Transmission ElectronMicroscopy - DOE contact Dean Miller, (630) 252-4108;Photon Imaging, Inc. contact Dr. Bradley E. Patt,(818) 709-2468

Using Convergent Beams for Small-Sample,Time-of-Flight Neutron Diffraction - DOE contact HelenKerch, (301) 903-2346; X-ray Optical Systems, Inc.contact David Usher, (518) 464-3334

Four Probe Stage and Holder for Transmission ElectronMicroscope - DOE contact Dean Miller, (630) 252-4108;Zyvex Corporation contact Timothy M. Gilmoir,(972) 235-7881



Sol-Gel Derived Neutron Detector Using a LithiatedGlass - DOE contact Helen Kerch, (301) 903-2346;Neutron Sciences, Inc. contact Andrew Stephan,(865) 523-0775

Development of an Ultra-Bright Electron Source forScanning Transmission Electron Microscopy - DOEcontact Dean Miller, (630) 252-4108; Nion Co. contactG. J. Corbin, (425) 576-9060

Pixel-Cell Neutron Detector and Read-Out SystemMeeting Requirements of Present and Future NeutronScattering Facilities - DOE contact Helen Kerch,(301) 903-2346; Ordela, Inc. contact Daniel M. Kopp,(865) 483-8675

Novel Neutron Detector for High Rate ImagingApplications - DOE contact Helen Kerch,(301) 903-2346; Proportional Technologies, Inc. contactDr. Jeffrey L. Lacy, (713) 747-7324


PHASE I

LITS-Forming for Pre-Bending of AlumiunumHydroformed Truck Frames - DOE contact MikeKassner, (541) 737-7023; Native AmericanTechnologies Company contact Valerie L. Rhoades,(303) 279-7942

Development of a New, Low Frequency, Rf-FocusedLinac Structure - DOE contact Jehanne Simon-Gillo,(301) 903-1455; Linac Systems contact Barbara C.Swenson, (505) 798-1904

SMALL BUSINESS TECHNOLOGY TRANSFERRESEARCH PROGRAM


PHASE I

Carbon Fiber Composite Aeroelastically Tailored RotorBlades for Utility-Scale Wind Turbines - DOE contactJohn Cadogan, (202) 586-1991; K. Wetzel & Companycontact Dr. Kyle K. Wetzel, (785) 766-2450

Insulation Coating of Rutherford Cable for AcceleratorApplications - DOE contact Jerry Peters,(301) 903-3233; Global Research & Development, Inc.contact Michael Tomsic, (937) 332-0348

Fiber Optic Scintillator System for Detection of BetaEmitters in Groundwater - DOE contact Brendlyn Faison,(301) 903-0042; Adherent Technologies, Inc. contactDr. Ronald E. Allred, (505) 346-1685



Advanced Membrane Technology for Biosolvents - DOEcontact Charlie Russomanno, (202) 586-7543; VertecBiosolvents, Inc. contact James E. Opre, (847) 803-0575

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PHASE I

Hydroforming of Light Weight Components fromAluminum and Magnesium Sheet and Tube - DOEcontact Mike Kassner, (541) 737-7023; AppliedEngineering Solutions, LLC contact David Guza,(614) 789-9890

Carbon/Glass Hybrid Wind Turbine Blades - DOE contactJohn Cadogan, (202) 586-1991; ILT Corporation dbaThink Composite contact Dr. Stephen W. Tsai,(650) 322-9433



Neutron Scattering Instrumentation for Measurementof Melt Structure - DOE contact Helen Kerch,(301) 903-2346; Containerless Research, Inc.contact John Nordine, (847) 467-2678


PHASE I

Waveshifters and Scintillators for Ionizing RadiationDetection - DOE contact Michael P. Procario,(301) 903-2890; Ludlum Measurements, Inc.contact Donald Ludlum, (915) 235-5494



Virtual-Impact Particle Sizing for Precursor Powders ofNb3Sn and Bi-2212 Superconductors - DOE contactJerry Peters, (301) 903-3233; Accelerator TechnologyCorporation contact Peter McIntyre, (979) 255-5531

Innovative Processing Methods for SuperconductingMaterials - DOE contact Jerry Peters, (301) 903-3233;Alabama Cryogenic Engineering, Inc. contact Mary T. Hendricks, (256) 536-8629

Oxide Dispersed Nanofluids for Next Generation HeatTransfer Fluids - DOE contact Glenn Strahs,(202) 586-2305; Nanopowder Enterprises, Inc.contact Dr. Gary S. Tompa, (732) 885-1088

Plasma Spraying of Nd2Fe12B Permanent MagnetMaterials - DOE contact Sam Bader, (630) 252-4960;Aps Material, Inc. contact Joseph Cheng,(937) 278-6547

OFFICE OF FUSION ENERGY SCIENCES

The mission of the Office of Fusion Energy Sciences(OFES) is to advance plasma science, fusion science,and fusion technology—the knowledge base needed foran economically and environmentally attractive fusionenergy source. Fusion materials research is a keyelement of the longer-term OFES mission, focusing onthe effects on materials properties and performancefrom exposure to the radiation, energetic particle,thermal, and chemical environments anticipated in thechambers of fusion experiments and energy systems.

The unique requirements on materials for fusionapplications are dominated by the intense energeticneutron environment characteristic of the deuterium-tritium fusion reaction. Materials in the fusion chambermust have slow and predictable degradation ofproperties in this neutron environment. For safety andenvironmental considerations, "low activation" materialsmust be selected with activation products that neitherdecay too rapidly (affecting such safety factors assystem decay heat) nor too slowly (affecting the wastemanagement concerns for end-of-life systemcomponents).

Structural materials research focuses on issues of microstructural stability, fracture and deformation mechanics,and the evolution of physical and mechanical properties.This research provides a link between fusion and othermaterials science communities and contributes in nicheareas toward grand challenges in general fields ofmaterials science. Growth in the theory, modeling, andsimulation elements of this research are providing forleveraging of advances in nano-technology andcomputational materials science research.

Non-structural materials research focuses on plasma-facing materials that protect structural materials fromintense heat and particle fluxes and extract surface heatdeposited by plasmas without rapid deterioration and oremitting levels of impurities that could degrade plasmaperformance.

Fusion materials research is conducted with ahigh degree of international cooperation. Bilateralagreements with Japan enhance the ability of eachparty to mount fission reactor irradiation experiments.Agreements under the International Energy Agencyprovides for the exchange of information and thecoordination of fusion materials programs in the U.S.,Japan, Europe, Russia, and China. The DOE contact isS. Berk (301) 903-4171.

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265. VANADIUM ALLOY AND INSULATING COATINGRESEARCH$2,000,000 DOE Contact: S. Berk (301) 903-4171ORNL Contact: S. Zinkle (865) 576-7220

Research is aimed at vanadium-based alloys forstructural application in the chambers of fusion systems.The goals of the research, which focuses on the V-Cr-Tisystem, are to identify promising candidate compositions,determine the properties of candidate alloys, andevaluate the response to irradiation conditions foranticipated fusion system operation. Critical issuesinclude irradiation embrittlement (loss of fracturetoughness), high-temperature creep, impurity corrosion,and joining. Compatibility studies are conducted betweenvanadium alloys and other candidate fusion materials,focusing on the effects of exposure to candidate coolants.Research is also conducted on electrically insulatingcoatings for elevated temperature environments. Thiswork identifies promising candidate coating systems,develops coating technology, and conducts theexperiments to demonstrate stability and self-repairneeded for fusion applications. Work on vanadium alloysinvolves irradiation in fission reactors, including HFIR andother test reactors, as partial simulation of the fusionenvironment. A modeling activity complements theexperimental measurements.

Keywords: Vanadium, Compatibility, Lithium,Irradiation Effects, Alloy, Coatings

266. THEORY AND MODELING $1,200,000DOE Contact: S. Berk (301) 903-4171UCLA Contact: Nasr Ghoniem (310) 825-4866

Models and computer simulation, validated withexperimental data, are combined to extend theunderstanding of the primary damage processes fromirradiation effects. Research is directed at developing afundamental understanding of both the basic damageprocess and microstructural evolution that takes place ina material during neutron irradiation.. The goal is toestablish models and methods that are able toextrapolate from the available data base to predict thebehavior of structural components in fusion systems.Special attention is given to the energy range appropriatefor the 14 MeV neutrons. Multiscale modeling appliesresults to evaluate the effects on properties of materials,especially the interactions of the irradiation produceddefects with the flow dislocations during deformationprocesses. Investigations are conducted on (a) the limitsof strength and toughness of materials based ondislocation propagation and interactions with crystalline

matrix obstacles (b) changes to thermal and electricalconductivity in materials based on electron and photontransport and scattering at the atomic level (c) plasticinstabilities and fracture processes in materialsirradiated under projected fusion conditions, and (d)effects of the many materials, irradiation, andmechanical loading parameters on flow and fractureprocesses to establish understanding of controllingmechanisms. Techniques include atomistic computersimulation, atomic cluster modeling, Monte Carloanalysis, 3-D dislocation dynamics, and flow andfracture models. Research includes materials andconditions relevant to inertial fusion systems as well asmagnetic systems.

Keywords: Modeling, Simulation, Irradiation Effects

267. FERRITIC/MARTENSITIC STEEL RESEARCH$1,900,000DOE Contact: S. Berk (301) 903-4171ORNL Contacts: S. J. Zinkle (865) 576-7220

Research is aimed at iron-based alloys for structuralapplication in the chambers of fusion systems. The goalsof the research, which focuses on advancedferritic/martensitic steel systems, are to identifypromising candidate compositions, determine theproperties of leading candidate alloys, and evaluate theresponse to irradiation conditions that simulateanticipated fusion system operation. Critical issuesinclude irradiation embrittlement (focusing on DBTTtransition shifts and loss of fracture toughness) and hightemperature creep. Innovative nanocomposited steelsare being explored for higher temperature applicationsthat currently available ferritic steels. Work on thismaterial class involves irradiation in fission reactors,including HFIR and other test reactors, as partialsimulation of the fusion environment. A modeling activitycomplements the experimental measurements.

Keywords: Steels, Irradiation Effects

268. SIC/SIC COMPOSITES RESEARCH $1,500,000DOE Contact: S. Berk (301) 903-4171PNNL Contacts: R. J. Kurtz (509) 373-7515

Research is aimed at SiC/SiC composites for structuralapplication in the chambers of fusion systems. Thisresearch is directed at furthering the understanding ofthe effects of irradiation on the SiC/SiC compositesystems as the basis for developing superior compositematerials for fusion structural applications. The focus ofthe work is on the evaluation of improved fibers andalternative interface layer materials. Critical issuesinclude irradiation-induced reduction in thermalconductivity, leak-tightness, joining, and helium effects.Work on this material class involves irradiation in fission

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reactors, including HFIR and other test reactors, aspartial simulation of the fusion environment. A modelingactivity complements the experimental measurements.

Keywords: Silicon Carbide, Composites, IrradiationEffects

269. PLASMA FACING MATERIALS RESEARCH $1,800,000DOE Contact: S. Berk (301) 903-4171SNL Contact: M. Ulrickson (505) 845-3020

Plasma-facing materials must withstand high heat andparticle fluxes from normal operation of fusion plasmas,survive intense surface energies from abnormal fusionplasma operation, such as plasma disruptions, withstandradiation damage by energetic neutrons, achievesufficient lifetimes and reliability to minimise replacementfrequency, and provide for reduced neutron activation tominimize decay heat and radioactive waste burdens.Research activities include improved techniques forjoining beryllium or tungsten to copper alloys,development of joining techniques for refractory metals(e.g., W, Mo, Nb, V), development of enhancementschemes for helium cooling or liquid lithium cooling ofrefractory alloys, and thermal fatigue testing of tungstenand other refractory materials. The joining techniquesbeing investigated include diffusion bonding, hot-isostaticpressing, furnace brazing and inertial welding. Tritiumretention and permeation measurements are conductedin the Tritium Plasma Experiment and the PISCESplasma simulator facility. Refractory material work iscentered on developing high temperature helium gascooled or liquid metal cooled heat sinks for plasma facingcomponents. The thermal fatigue testing and heatremoval capability measurements are carried out onelectron beam test systems.

Keywords: Plasma-Facing Materials, Refractory Metals

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OFFICE OF ENVIRONMENTAL MANAGEMENT

FY 2002

OFFICE OF ENVIRONMENTAL MANAGEMENT - GRAND TOTAL $3,602,996


Atmospheric-Pressure Plasma Cleaning of Contaminated Surfaces 366,666Radiation Effects on Sorption and Mobilization of Radionuclides During Transport

Through the Geosphere 200,000Iron Phosphate Glasses: An Alternative for Vitrifying Certain Nuclear Wastes 173,333Radiation Effects in Nuclear Waste Materials 313,333New Metal Niobate and Silicotitanate Ion Exchangers: Development and Characterization 300,000Corrosion of Spent Nuclear Fuel: The Long-Term Assessment 148,333Direct Investigations of the Immobilization of Radionuclides in the Alteration Products of

Spent Nuclear Fuel 342,000Physical, Chemical and Structural Evolutioon of Zeolite-Containing Waste Forms Produced from

Metakaolinite and Calcined HLW 196,666Investigating Ultrasonic Diffraction Grating Spectroscopy and Reflection Techniques for

Characterizing Slurry Properties 229,333Chemistry of Actinides in Molten Glasses and its Correlation to Structural Performance of

Solid Glasses: Filling the Knowledge Gap 213,333Stability of High Level Radioactive Waste Forms 286,666Physical Characterization of Solid-Liquid Slurries at High Weight Fractions Utilizing Optical

and Ultrasonic Methods 273,333Assessing the State and Distribution of Radionuclide Contamination in Concrete: An Experimental

and Modeling Study of the Dynamics of Contamination 300,000Underground Corrosion After 32 Years: A Study of Fate and Transport 260,000


126

OFFICE OF ENVIRONMENTAL MANAGEMENT

The Office of Environmental Management (EM) was established to effectively coordinate and manage the Department'sactivities to remediate the DOE Defense Complex and to properly manage waste generated by current operations. EMconducts materials research within two offices:

Office of Waste Management - The Office of Waste Management uses current technologies to minimize production of DOE-generated waste, alter current processes to reduce waste generation, and work with the Office of Science and Technologyto develop innovative technologies for the treatment and disposal of present and future waste streams. The mission of theOffice is to minimize, treat, store, and dispose of DOE waste to protect human health, safety, and the environment.

Office of Science and Technology - The Office of Science and Technology (OST) is responsible for managing and directingtargeted basic research and focused, solution-oriented technology development programs to support the DOE Office ofEnvironmental Management (EM). Programs involve research, development, demonstration, and deployment activities thatare designed to produce innovative technologies and technology systems to meet national needs for regulatory compliance,lower life-cycle costs, and reduced risks to both people and the environment. Certain areas of the OST program focus onmaterials research in order to provide better, safer and less expensive approaches to identify, characterize and remediateDOE's waste problem.

Four Focus Areas have been formed to focus the EM-wide technology development activities on DOE's most pressingenvironmental management problems and are co-led by all EM offices:

Subsurface Contaminants. Hazardous and radioactive contaminants in soil and groundwater exist throughout the DOEcomplex, including radionuclides, heavy metals, and dense, nonaqueous phase liquids. Groundwater plumes havecontaminated over 600 billion gallons of water and 50 million cubic meters of soil. In addition, the Subsurface ContaminantsFocus Area is responsible for supplying technologies for the remediation of numerous landfills at DOE facilities. Technologydeveloped within this speciality area provides effective methods to contain contaminant plumes and new or alternativetechnologies for remediating contaminated soils and groundwater.

Radioactive Tank Waste Remediation. Across the DOE Complex, hundreds of large storage tanks contain hundreds ofthousands of cubic meters of high-level mixed waste. Primary areas of concern are deteriorating tank structures andconsequent leakage of their contents. Research and technology development activities must focus on the development ofsafe, reliable, cost-effective methods of characterization, retrieval, treatment, and final disposal of the wastes.

Mixed Waste Characterization, Treatment, and Disposal. DOE faces major technical challenges in the management of low-level radioactive mixed waste. Several conflicting regulations together with a lack of definitive mixed wastetreatment standards hamper mixed waste treatment and disposal. Disposal capacity for mixed waste is also expensive andseverely limited. DOE now spends millions of dollars annually to store mixed waste because of the lack of acceptedtreatment technology and disposal capacity. In addition, currently available waste management practices require extensive,and hence costly waste characterization before disposal. Therefore, DOE must pursue technology that leads to better andless expensive characterization, retrieval, handling, treatment, and disposal of mixed waste.

Decontamination and Decommissioning. The aging of DOE's weapons facilities, along with the reduction in nuclear weaponsproduction, has resulted in a need to transition, decommission, deactivate, and dispose of numerous facilities contaminatedwith radionuclides and hazardous materials. While building and scrap materials at the sites are a potential resource, with asignificant economic value, current regulations lack clear release standards. Thisindirectly discourages the recovery, recycling, and/or reuse of these resources. The development of enhanced technologiesfor the decontamination of these materials, and effective communication of the low relative risks involved, will facilitate therecovery, recycle, and/or reuse of these resources. Improved materials removal, handling, and processing technologies willenhance worker safety and reduce cost.

The projects listed in this report are managed under the Environmental Management Research Program (EMSP). Basicresearch under the EMSP contributes to environmental management activities that decrease risk to the public and workers,provide opportunities for major cost reductions, reduce time required to achieve EM's mission goals, and, in general,address problems that are considered intractable without new knowledge. This program is designed to inspire breakthroughsin areas critical to the EM mission through basic research and is managed in partnership with ER. ER's well-establishedprocedures are used for merit review of applications to the EMSP. Subsequent to the formal scientific merit review,applications that are judged scientifically meritorious are evaluated by DOE for relevance to the objectives of the EMSP. The


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FY 2002 EMSP portfolio consisted of approximately 200 awards amounting to a total of approximately $150 million in three-year funding. Fourteen of those awards were in scientific disciplines related to materials issues that have potential to solveEnvironmental Management challenges. The FY 2002 component of materials research is estimated to amount to$3,602,996. The entire EMSP portfolio can be viewed on the World Wide Web by accessing the EMSP home page athttp://emsp.em.doe.gov. The EMSP program was transferred to the Office of Science in FY 2003. The EMSP Director forFY2002 was Mark Gilbertson. The current EMSP Director is Roland F. Hirsch (301) 903-9009.


270. ATMOSPHERIC-PRESSURE PLASMACLEANING OF CONTAMINATED SURFACES$366,666DOE Contact: Roland F. Hirsch (301) 903-9009University of California at Los Angeles Contact:

Robert F. Hicks (310) 206-6865LANL Contact: Hans Herrmann (505) 665-6157

Decommissioning of transuranic waste (TRU) into low-level radioactive waste (LLW) represents the largestcleanup cost associated with the nuclear weaponscomplex. This project is developing a low-cost technologyfor converting TRU into LLW based on the selectiveplasma etching of plutonium and other actinides fromcontaminated structures. Plasma etching has alreadybeen used to remove Pu films from materials. However,this process is operated under vacuum, making it bothexpensive and difficult to apply to many nuclear wastes.A major breakthrough in this field was the demonstrationof the operation of a g-mode, resonant-cavity,atmospheric-pressure plasma jet (APPJ). This jet etcheskapton at between 10 and 15 m/hour, and tantalum atbetween 1 and 2 m/hour. Etching occurs below 373 K, sothat delicate materials will not be destroyed by thisprocess. The plasma jet may be used to selectivelyremove plutonium and other actinide elements byconverting them into volatile compounds that are trappedby adsorption and filtration. Since the jet operates outsidea chamber, many nuclear wastes may be treated,including machinery, duct-work, concrete and otherbuilding materials. At LANL, the source physics is beingstudied using Stark-broadening, microwaveinterferometry, and laser-induced fluorescence (LIF). Themetastables, neutrals and radical species produced withmixtures of NF3, CF4, C2F6, O2,He and Ar are beingidentified by LIF, optical emission spectroscopy (OES),laser Raman spectroscopy (LRS), coherent anti-StokesRaman spectroscopy (CARS), and mass spectroscopy(MS). At UCLA, the elementary surface reactions of thesespecies with tantalum and tungsten (surrogate metals forPu) are being studied in ultrahigh vacuum using asupersonic molecular-beam coupled to the plasma jet.The surfaces are being characterized by X-rayphotoemission (XPS), infrared spectroscopy (IR), low-energy electron diffraction (LEED), and scanning-tunneling microscopy (STM). In addition, plutoniumetching experiments are being carried out at the LosAlamos Plutonium Facility. Recent improvements in the

source design have made it compact, rugged, reliableand easily configured to treat objects of different sizesand shapes. The objectives of this research program areto fully characterize the discharge physics and chemistry,to engineer the exhaust containment system, and to testthe plasma device on contaminated structures within theDepartment of Energy complex.

Keywords: Plasma Etching, Plutonium

271. RADIATION EFFECTS ON SORPTION ANDMOBILIZATION OF RADIONUCLIDES DURINGTRANSPORT THROUGH THE GEOSPHERE$200,000DOE Contact: Roland F. Hirsch (301) 903-9009University of Michigan Contacts: Lu-Min Wang

(313) 647-8530

Site restoration activities at DOE facilities and thepermanent disposal of nuclear waste inevitably involveunderstanding the behavior of materials in a radiationfield. Radionuclide decay and associated radiation effectslead to physical and chemical changes in importantproperties (e.g., sorption and cation exchange capacity).During the past three years, radiation effects in selectednear-field materials have been evaluated in acceleratedlaboratory experiments utilizing energetic electrons andions and in situ transmission electron microscopy (TEM).Zeolites and layered silicates were found to be highlysusceptible to irradiation-induced solid-stateamorphization. The critical doses for completeamorphization of these phases are as low as <0.1displacement per atom (dpa) or 108 GY in ionizationenergy deposition (i.e., the dose for a zeolite with 10wt.% loading of 137Cs in 400 years). Even partialamorphization will cause a dramatic reduction (up to95%) in ion-exchange and sorption/desorption capacitiesfor radionuclides, such as Cs and Sr. Because the near-field or chemical processing materials, e.g., zeolites orcrystalline silicotitanate (CST), will receive a substantialradiation dose after they have incorporated radionuclides,the results suggest that radiation may, in some cases,retard the release of sorbed or ion-exchangedradionuclides. These results have a direct bearing onrepository performance assessments (e.g., theextent to which zeolites can retard the release ofradionuclides) and on the technologies used to processhigh-level liquid waste (e.g., separation of 137Cs fromHLW using CST at the Savannah River Site).


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Radionuclides to be studied include Cs, Sr, U, and Se,which are important because: 1)they represent a range ofsorptive behavior that should bracket the behavior ofmost other radionuclides (except 99Tc) and 2) they areconsidered to make important contributions to totalradiation exposures, as illustrated in the recent TotalSystems Performance Assessment-Viability Assessmentof the proposed repository at Yucca Mountain. Selectedclay and zeolite samples will be irradiated with highenergy electrons, high energy ions and neutrons tosimulate the radiation effects from a variety of radioactivedecay processes at a much accelerated rate using aunique combination of irradiation facilities available at theUniversity of Michigan (the Ford Nuclear Reactor and theMichigan Ion Beam Laboratory). Ion exchange/sorptionexperiments will be conducted on samples irradiated tovarious doses to determine the impact of the radiationeffects on the sorption capacity and retention ofradionuclides. Novel ion implantation and surfaceanalysis techniques, e.g., atomic force microscopy andZ-contrast high resolution scanning transmission electronmicroscopy (STEM), will be used to identify atomic-scaleeffects of radiation damage associated with single orsmall clusters of radionuclides sorbed onto mineralsurfaces.

Keywords: Radiation Effects, Near-field, GeologicRepository

272. IRON PHOSPHATE GLASSES: ANALTERNATIVE FOR VITRIFYING CERTAINNUCLEAR WASTES$173,333DOE Contact: Roland F. Hirsch (301) 903-9009University of Missouri-Rolla Contact:

Delbert E. Day (573) 341-4354

Borosilicate glass is the only material currently approvedand being used to vitrify high level nuclear waste.Unfortunately, many high level nuclear waste feeds in theU.S. contain components which are chemicallyincompatible with borosilicate glasses. Current plans callfor vitrifying even these problematic waste feeds inborosilicate glasses after the original waste feed hasbeen pre-processed and/or diluted to compensate for theincompatibility. However, these pre-treatment processes,as well as the larger waste volumes resulting fromdilution, will add billions of dollars to the DOE's cost ofcleaning up the former nuclear weapons productionfacilities. Such additional costs may be avoided bydeveloping a small number of alternative waste glasseswhich are suitable for vitrifying those specific waste feedsthat are incompatible with borosilicate glasses.

A low cost and technically effective alternative waste formbased on a new family of iron-phosphate glasses whichappear to be well suited for many waste feeds, especiallythose which are incompatible with borosilicate glasses,

has recently been developed. However, the scientific andtechnical knowledge base that is needed to vitrify nuclearwaste in iron phosphate glasses on a production scale iscurrently lacking. In addition, the high priority wastes thatare likely to cause problems in borosilicate melts need tobe identified and property data need to be acquired foriron phosphate wasteforms made from these wastes.This research is addressing these needs, usingtechniques such as EXAFS, XANES, XPS, X-ray andneutron diffraction, IR, SEM, Mössbauer spectroscopyand DTA/DSC to obtain the information needed todemonstrate that iron phosphate glasses can be used tovitrify those nuclear wastes which are poorly suted forborosilicate glasses.

Keywords: Iron Phosphate Glasses, Vitrification,Nuclear Waste

273. RADIATION EFFECTS IN NUCLEAR WASTEMATERIALS$313,333DOE Contact: Roland F. Hirsch (301) 903-9009PNNL Contact: William J. Weber (509) 376-3644

The objective of this project is to develop a fundamentalunderstanding of radiation effects in glass and ceramics,as well as the influence of radiation effects on aqueousdissolution kinetics. This study will provide theunderpinning science to develop improved glass andceramic waste forms for the immobilization anddisposition of high-level tank waste, excess plutonium,plutonium residues and scrap, surplus weaponsplutonium, other actinides, and other nuclear wastestreams. Furthermore, this study will develop predictivemodels for the performance of nuclear waste forms andstabilized nuclear materials. The research focuses on theeffects of alpha and beta decay on defect production,defect interactions, diffusion, solid-state phasetransformations, and gas accumulation, and dissolutionkinetics. Plutonium incorporation, gamma irradiation, ion-beam irradiation, and electron beam irradiation are usedto simulate the effects of alpha decay and beta decay onrelevant glasses and ceramics in experimental studies.Computer simulation methods are used to provide anatomic-level interpretation of experimental data, calculateimportant fundamental parameters, and provide multi-scale computational capabilities over different length(atomic to macroscopic) and time (picoseconds tomillenia) scales.

Keywords: Glass, Ceramics, Radiation Effects


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274. NEW METAL NIOBATE AND SILICOTITANATEION EXCHANGERS: DEVELOPMENT ANDCHARACTERIZATION$300,000DOE Contact: Roland F. Hirsch (301) 903-9009PNL Contact: Yali Su (509) 376-5290SNL Contact: Tina Nenoff (505) 844-0340UC Davis Contact: Alexandra Navrotsky

(916) 752-3292

Previous research by this group provided preliminarydata of a novel class of niobate-based molecular sieves(Na/Nb/M/O, M transition metals) that show exceptionallyhigh selectivity for divalent cations under extremeconditions (acid solutions, competing cations) and novelsilicotitanate phases that are also selective for divalentcations. Furthermore, these materials are easilyconverted by a high-temperature in situ heat treatmentinto a refractory ceramic waste form with low cationleachability. The new niobate-based waste form is aperovskite phase, which is also a major component ofSynroc, a titanate ceramic waste form used forsequestration of high-level wastes (HLW) fromreprocessed, spent nuclear fuel. These new niobate ionexchangers also showed orders of magnitude betterselectivity for Sr2+ under acid conditions than any othermaterial.

The goal of this project is to provide DOE with alternativematerials that can exceed the performance ofmonosodium titanate (MST) for strontium and actinideremoval at the Savannah River Site (SRS), removestrontium from acidic waste at Idaho NationalEngineering and Environmental Laboratory (INEEL), andsequester divalent cations from contaminatedgroundwater and soil plume. The research team willfocus on three tasks that will provide both the basicresearch necessary for the development of highlyselective ion exchange materials and also materials forshort-term deployment within the DOE complex:1) structure/property relationships of a novel class ofniobate based molecular sieves (Na/Nb/M/O,M=transition metals), which show exceptionally highselectivity for divalent cations under extreme conditions(acid solutions, competing cations); 2) the role of ionexchanger structure change (both niobates andsilicotitanates) on the exchange capacity (for elementssuch as strontium and actinide-surrogates), whichresultfrom exposure to DOE complex waste simulants;3) thermodynamic stability of metal niobates andsilicotitanate ionexchangers.

Keywords: Niobate, Silicotitanate, Ion Exchanger

275. CORROSION OF SPENT NUCLEAR FUEL: THELONG-TERM ASSESSMENT$148,333DOE Contact: Roland F. Hirsch (301) 903-9009University of Michigan Contact: Rodney C. Ewing

(313) 647-8529

Spent nuclear fuel accounts for over 95% of the totalradioactivity in the radioactive wastes in the United Statesthat require disposal, disposition, or remediation. TheUO2 in spent nuclear fuel is not stable under oxidizingconditions. Under oxidizing conditions, the U(IV) has astrong tendency to exist as U(VI) in the uranyl molecule,UO2

2+. The uranyl ions react with a wide variety ofinorganic and organic anions to form complexes whichare often highly soluble. The result is rather rapiddissolution of UO2 and the formation of a wide variety ofuranyl oxide hydrates, uranyl silicates and uranylphosphates. The kinetics for this transformation are rapid,essentially instantaneous on geologic time scales. Underreducing conditions, UO2 is stable, but may alter to U4+

compounds such as coffinite, USiO4, depending ongroundwater compositions. Under both oxidizing andreducing conditions, the formation of new uraniumphases may lead to the release or retardation of traceelements, such as the fission product elements andactinides in spent nuclear fuel. Over the long term, anddepending on the extent to which the secondary uraniumphases can incorporate fission products and actinides,these alteration phases become the near-field sourceterm.

Fortunately, previous experimental studies and fieldstudies have established that natural uranite and itsalteration products are good "natural analogues" forstudying the corrosion of UO2 in spent nuclear fuel. Thisresearch program is addressing the following issues:

1) What are the long-term corrosion products ofnatural UO2+x, uraninite, under oxidizing andreducing conditions?

2) What is the paragenesis or the reaction path of thephases that form during alteration? How is thesequence formation related to the structure of theseuranium phases and reacting groundwatercomposition?

3) What is the trace element content in the corrosionproducts as compared to the original UO2+x? Do thetrace element contents substantiate modelsdeveloped to predict radionuclide incorporation intothe secondary phases?

4) Are the corrosion products accurately predictedfrom geochemical codes (e.g., EQ3/6) that are usedin performance assessments?


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5) How persistent over time are the metastable phaseassemblages that form? Will these phases serve aseffective barriers to radionuclide release?

Experimental results and theoretical models for thecorrosion of spent nuclear fuel under oxidizing andreducing conditions will be tested by comparison toresults from studies of samples from the Oklo naturalfission reactors.

Keywords: Uranium Oxides, Minerology, Corrosion,Phase Stability

276. DIRECT INVESTIGATIONS OF THEIMMOBILIZATION OF RADIONUCLIDES IN THEALTERATION PRODUCTS OF SPENT NUCLEARFUEL$342,000DOE Contact: Roland F. Hirsch (301) 903-9009University of Notre Dame Contact: Peter C. Burns

(219) 631-5380Argonne National Laboratory Contact:

Dr. Robert J. Finch (630) 252-9829

This project emphasizes the synthesis of uranium phasesand uranium phases doped with certain radionuclides inorder to examine radionuclide incorporation in uranylcompounds. The identities of alteration phases importantfor spent-fuel corrosion will be gleaned from the results oflong-term experiments on the corrosion of spent UO2 fueland unirradiated UO2, as well as more recent studies ofU-metal fuel corrosion, that are currently underway atANL. The focus will be on synthesizing actinidecompounds similar to those that have been identified ascorrosion products of spent uranium-based fuels. Thegoals of the experiments are to synthesize andcharacterize actinide and fission-product host phasesformed on U-based waste forms under oxidizingconditions, such as expected at the candidategeological repository at Yucca Mountain. Target phasesfor synthesis include those identified in current corrosionexperiments with U-based fuels being conducted atArgonne. Those experiments demonstrate that manyradionuclides are retained in U-bearing alterationproducts. Synthesis and characterization of U(VI) phasesdoped with specific radionuclides helps clarify themechanisms of radionuclide incorporation into uranyl-based compounds. Where possible, stable-isotopeequivalents of radionuclides are used during synthesis;however, pure Np and Pu analogues of selected uraniumcompounds will also be synthesized. In addition, Ucompounds doped with low levels of selectedradionuclides will be characterized in order to understandmechanisms of trace-element substitution.Methods used to characterize solid phases include X-raypowder diffraction and transmission electron microscopy.Selected samples are also analyzed by single-crystal X-

ray structure analyses and X-ray absorptionspectroscopy, where possible.

Keywords: Uranium Oxides, Minerology, PhaseStability, Corrosion, Radionuclides

277. PHYSICAL, CHEMICAL AND STRUCTURALEVOLUTION OF ZEOLITE-CONTAINING WASTEFORMS PRODUCED FROM METAKAOLINITEAND CALCINED HLW$196,666DOE Contact: Roland F. Hirsch (301) 903-9009Pennsylvania State University Contact:

Michael Grutzeck (814) 863-2779Savannah River Technology Center Contact:

Carol M. Jantzen (803) 725-2374

Natural and synthetic zeolites are extremely versatilematerials. They can adsorb a variety of liquids and gases,and also take part in cation exchange reactions. Zeolitesare easy to make, they can be synthesized from a widevariety of natural and man made materials. One suchcombination is metakaolinite and sodium hydroxidesolution. The objective of this research is to adapt thiswell known reaction for use in site remediation and clean-up of caustic waste solutions now in storage in tanks atHanford and the Savannah River sites.

It has been established that a mixture of calcinedequivalent ICPP waste (sodium aluminate/hydroxidesolution containing 3:1 Na:Al) and fly ash and/ormetakaolinite can be cured at various temperatures toproduce a monolith containing Zeolite A (80°C) or Na-P1plus hydroxysodalite (130°C) dispersed in an alkalialuminosilicate hydrate matrix. The zeolitization processis a simple one and as such could be a viable alternativefor fixation of low activity waste (LAW) salts and calcines.Dissolution tests have shown these materials to havesuperior retention for alkali, alkaline earth and heavymetal ions.

The technology for synthesizing zeolites is welldocumented for pure starting materials, but relatively littleis known about the process if metakaolinite is mixed witha complex mixture of oxides containing nearly everyelement in the periodic table. The purpose of theproposed work is to develop a clearer understanding ofthe advantages and limitations of producing a zeolite-containing waste form from calcined radioactive waste,i.e. the effect of processing variables, reaction kinetics,crystal and phase chemistry, and microstructure on theirperformance. To accomplish this, two waste formsrepresentative of solutions in storage at the Hanford andSavannah River sites will be simulated. Because nitrateis detrimental to the process, the LAW will be calcined atvarious temperatures (w/wo sugar) to maximize thereactivity of the resultant mix of oxide phases whileminimizing the loss of volatiles. The oxides will be mixed


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with varying amounts and types of metakaolinite, smallamounts of other chemicals (alkali hydroxides and/orcarbonates, zeolite seeds, templating agents) andenough water to make a paste. The paste will then becured (in-can) at a variety of temperatures (80°-100°C).Once reaction rates for the process are established, MASNMR and TEM will be used to study the atomic-levelstructure of the solids. X-ray diffraction will be used toexamine the degree of crystallinity of the waste forms. Anenvironmental SEM will be used to track the developmentof microstructure in real time. An electron microprobe willbe used to analyze the phases in the waste form.Attempts will be made to relate changes in phasechemistry and microstructure to distribution coefficientsand dissolution data. Compressive and bending strengthtests will be used to determine mechanical behavior andstandard leach tests will be used to determine thepotential consequences of cation exchange reactions.Since simulated waste is not an adequate predictor, amajor portion of the proposed work will be carried out atthe Savannah River Technology Center, using actualLAW samples obtained from the Savannah River site.

Keywords: Zeolites, Radioactive Waste

278. INVESTIGATING ULTRASONIC DIFFRACTIONGRATING SPECTROSCOPY AND REFLECTIONTECHNIQUES FOR CHARACTERIZING SLURRYPROPERTIES$229,333DOE Contact: Roland F. Hirsch (301) 903-9009Pacific Northwest National Laboratory Contact:

Margaret S. Greenwood (509) 375-6801University of Washington Contact:

Lloyd W. Burgess (206) 543-0579

The U.S. Department of Energy (DOE) has millions ofgallons of radioactive liquid and sludge wastes that mustbe retrieved from underground storage tanks. This waste,in the form of slurries, must be transferred and processedto a final form, such as glass logs. On-lineinstrumentation to measure the properties of theseslurries in real-time during transport is needed in order toprevent plugging and reduce excessive dilution. Thisproject is a collaborative effort between Pacific NorthwestNational Laboratory (PNNL) and the University ofWashington to develop a completely new method forusing ultrasonics to measure the particle size andviscosity of a slurry. The concepts are based on work inoptics on grating-light-reflection spectroscopy (GLRS) atthe University of Washington and some preliminary workon ultrasonic diffraction grating spectroscopy (UDGS)that has already been carried out at PNNL. The projectobjective is to extend the GLRS theory for optics toultrasonics, and to demonstrate its capabilities of UDGS.The viscosity of a slurry is measured by using themultiple reflections of a shear wave at the slurry-solidinterface. This new ultrasonic method could result in an

instrument that would be simple, rugged, and very small,allowing it to be implemented as part of a pipeline wall atfacilities across the DOE complex.

Keywords: Diffraction Grating, Spectroscopy,Ultrasonic, Slurry, Viscosity, Particle Size

279. CHEMISTRY OF ACTINIDES IN MOLTENGLASSES AND ITS CORRELATION TOSTRUCTURAL PERFORMANCE OF SOLIDGLASSES: FILLING THE KNOWLEDGE GAP$213,333DOE Contact: Roland F. Hirsch (301) 903-9009Oak Ridge National Laboratory Contact:

Sheng Dai (865) 576-7307Savannah River Technology Center Contact:

Ray F. Schumacher (803) 725-5991

Chemical processes occurring in molten glasses are keyelements in determining efficient immobilization and thelong term stability of glasses. The underlying goal of thisresearch is to make use of high-temperaturespectroscopic techniques to increase our fundamentalunderstanding of the vitrification process, specifically therelationship between the chemistry of molten glasses andthe structural features of final solid glasses. Thefundamental knowledge gained in this study will fill acrucial knowledge gap concerning chemistry of actinidesin molten glasses and have a broad impact on the designand construction of advanced vitrification processes. Hightemperature UV/Visible and near-IR spectral data will beused to investigate the solubility of actinide species invarious molten glasses as a function of the compositionand temperature. These data will be used to develop anew “optical basicity” scale for actinide stability andspeciation in oxide glasses in analogy to the common pHscale used to define the acid-base properties of aqueoussystems. Fluorescence lifetime distribution methods,fluorescence line-narrowing spectroscopy and X-rayabsorption spectroscopy (XAS) will provide informationon the local environment of the actinides while EPR andX-ray absorption edge positions will be used to define theoxidation states of actinide species in glasses. Thecombination of the optical basicity scale and structuralinformation from fluorescence and XAS investigations,will be used to produce a detailed description of theidentities and behavior of actinide species in silicate-based glasses. This stability model will be correlated toactinide leaching behavior for a glass matrix and offers asimple but powerful set of spectral “fingerprints” to predictthe behavior of actinide species when immobilized in aglass.

Keywords: Molten Glasses, Spectroscopy, X-rayAbsorption, Actinides


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280. STABILITY OF HIGH LEVEL RADIOACTIVEWASTE FORMS$286,666DOE Contact: Roland F. Hirsch (301) 903-9009Oak Ridge National Laboratory Contact:

Theodore M. Besmann (865) 574-6852Pacific Northwest National Laboratory Contact

John D. Vienna (509) 372-2807

High-level waste (HLW) glass compositions, processingschemes, limits on waste loading, and corrosion/dissolution release models are dependent on an accurateknowledge of liquidus temperatures and thermochemicalvalues. Unfortunately, existing models for the liquidus areempirically-based, depending on extrapolations ofexperimental information. In addition, present models ofleaching behavior of glass waste forms use simplisticassumptions of the thermochemistry or experimentallymeasured values obtained under non-realistic conditions.There is thus a critical need for both more accurate andmore widely applicable models for HLW glass behavior.In a previous project significant progress was made inmodeling HLW glass. Borosilicate glass was accuratelyrepresented along with the additional FeO-Fe2O3, Li2O,K2O, MgO, and CaO components. Nephelineprecipitation, an issue in Hanford HLW formulations, wasmodeled and shown to be predictive. The objective of thiseffort is to continue the development of a basicunderstanding of the phase equilibria and solid solution ofHLW glasses, incorporating other critical wasteconstituents including, S, Cr, F, P, actinides and rareearths. With regard to a fundamental understanding ofsolution oxides, there should be added insights on defectchemistry, interstitial behavior, clustering, and theenergetics of metal oxide solutes.

Keywords: High-Level Waste, Glass, Phase Equilibria

281. PHYSICAL CHARACTERIZATION OF SOLID-LIQUID SLURRIES AT HIGH WEIGHTFRACTIONS UTILIZING OPTICAL ANDULTRASONIC METHODS$273,333DOE Contact: Roland F. Hirsch (301) 903-9009Pennsylvania State University Contact:

Michael Grutzeck (814) 863-2779Savannah River Technology Center Contact:

Carol M. Jantzen (803) 725-2374

Liquid sodium-bearing waste (SBW) can be calcined andsolidified using metakaolinite and a limited amount ofwater. The processing does not require expensivespecialized equipment or exotic materials but rather it canbe done using conventional cement and/or concretemixing equipment. The final product is cured at relativelylow temperatures producing a dense ceramic-likematerial (hydroceramic) with strength in the 300-400 psirange and leach rates comparable to glass waste forms

with similar waste loading. This product is stable inrealistic geologic settings due to the in situ growth ofzeolites. Data from a previous project have shown thathydroceramics could well be a viable alternative forfixation of low activity sodium-bearing waste. Theobjective of this continuation study is to further adapt thistechnology for use in site remediation and clean-up ofcaustic waste solutions now in storage in tanks atHanford and the Savannah River sites. This work isaimed at developing a clearer understanding of theadvantages and limitations of producing a zeolite-containing hydroceramic from the low activity SBW atthese sites, i.e., the effect of processing variables,reaction kinetics, crystal and phase chemistry, andmicrostructure on the performance of the waste form. Inaddition, the processing method will be further refined toincrease waste loading in the hydroceramics, with theobjective of making the calcine fit the zeolitizationprocess as well as possible. It is anticipated that bytailoring the calcination process, it will be possible toencapsulate many more radionuclides without sacrificingthe performance of the waste form, thereby creating abetter hydroceramic waste form.

Keywords: Hydroceramic, Zeolites, Sodium-BearingWaste, Calcination

282. ASSESSING THE STATE AND DISTRIBUTIONOF RADIONUCLIDE CONTAMINATION INCONCRETE: AN EXPERIMENTAL ANDMODELING STUDY OF THE DYNAMICS OFCONTAMINATION$300,000DOE Contact: Roland F. Hirsch (301) 903-9009Lawrence Livermore National Laboratory Contact:

Brian Viani (925) 423-2001

There are hundreds of cement structures in the DOEcomplex that are contaminated by radionuclides andotherchemicals. A fundamental understanding of thefactors governing contaminant interactions in concrete isnecessary in order to evaluate and model contaminanttransport and develop more efficient methods for R&Defforts. The goal of this research is to enhance ourunderstanding of how radionuclides bind to concrete andto develop a more accurate predictive capability whichwill allow various decontamination approaches to beevaluated. This will be accomplished through acombination of laboratory-based experiments onradionuclide interactions with cementitious materials,along with state-of-the-art materials characterization andtransport modeling techniques. Transport studiesincluding flow-through and batch sorption tests will beinitiated using the radionuclides Cs, Tc, U, and Pu andordinary Portland cement with or without aggregates. Inaddition to standard radioanalytical and microscopicmethods, X-ray absorption spectroscopy will be used toprovide detailed, element-specific information on


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radionuclide speciation, including distribution, redoxactivity, and aging effects. Results from theseexperiments will be compared to characterization ofactual aged concrete cores from contaminated DOEfacilities. Transport modeling simulations will use thechemical parameters determined from the lab-basedexperiments and the materials characterization tasks topredict the depth of contaminant penetration and itschemical form and association in the concrete. Oursimulations explicitly account for fracture flow andmineralogical heterogeneity and will be used to predictthe effect of fractures and aggregate on the resultingradionuclide distribution. The team assembled here hasextensive background and experience in studyingradionuclide interactions with cementitious materials.

Keywords: Radionuclides, Contamination, Concrete,Modeling, Transport

283. UNDERGROUND CORROSION AFTER 32YEARS:A STUDY OF FATE AND TRANSPORT$260,000DOE Contact: Roland F. Hirsch (301) 903-9009Idaho National Engineering and Environmental

Laboratory Contact: Kay Adler Flitton (208) 526-0525

In 1970, the National Institute of Standards andTechnology (NIST) implemented the most ambitious andcomprehensive long-term corrosion behavior test to datefor stainless steels in soil environments. Thirty-threeyears have passed since scientists buried 6,324specimens from stainless steel types, specialty alloys,composite configurations, and multiple material formsand treatment conditions at six distinctive soil-type sitesthroughout the country. Today, there are more than 190specimens per site, exceeding a total of 1000 specimensthat remain undisturbed, a buried treasure of subsurfacescientific data. The objective of this research project is tocomplete the NIST corrosion study and thoroughlyexamine the soil and environment surrounding thespecimens. The project takes an interdisciplinaryresearch approach that will correlate the complicatedinterrelationships among metal integrity, corrosion rates,corrosion mechanisms, soil properties, soil microbiology,plant and animal interaction with corrosion products, andfate and transport of metallic ions. The results will providemuch needed data on corrosion rates, undergroundmaterial degradation, and the behavior of corrosionproducts in the near-field vadose zone. The data willimprove the ability to predict the fate and transport ofchemical and radiological contaminants at sitesthroughout the DOE complex. This research also directlyapplies to environmental management operational

corrosion issues, and long-term stewardship scientificneeds for understanding the behavior of waste forms andtheir near-field contaminant transport.

Keywords: Metals, Corrosion, Transport, Contaminants

Office of Nuclear Energy, Science and Technology

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OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY

FY 2002

OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY - GRAND TOTAL $12,730,821

OFFICE OF SPACE AND DEFENSE POWER SYSTEMS $3,781,000

SPACE AND NATIONAL SECURITY PROGRAMS $3,781,000


Maintain the Capabilities and Facilities to Produce DOP-26 Iridium Alloy Blank and Foil Stock Material, Manufacture Clad Vent Sets,and Manage the Iridium Inventory 1,720,000

Carbon-Bonded Carbon Fiber Insulation Production, Maintenance, Manufacturing Process Development, and Product Characterization 439,000


Alloy Development Characterization, Mechanical Property Testing, and Insulation Outgassing Assessment 1,105,000

Fabrication Development and Materials Production for AMTEC Converters 517,000

OFFICE OF TECHNOLOGY AND INTERNATIONAL COOPERATION $8,949,821

NUCLEAR ENERGY PLANT OPTIMIZATION $3,555,000


Steam Generator Non-Destructive Examination Test Mockup Facility 260,000Advanced Eddy-Current Inspection System for Detection and Characterization of

Defects in Steam Generator Tubes 290,000Develop Empirical Data to Characterize Aging Degradation of Polymers Used in

Electrical Cable 330,000Develop Condition Monitoring Techniques for Electrical Cable 270,000Mechanical Behavior of Irradiated Structural Stainless Steels 465,000Fatigue Management 400,000Assessment of Aging Effects on Components and Structures from Nuclear Power Plants 500,000Irradiation Induced Swelling and Stress Relaxation of PWR Reactor Core Internal

Components 40,000Mitigation of Initiation and Growth of PWSCC in Alloy 600 and 82/182 Weld Metals 125,000Validation of BWR Fluence Models and Weldability of Internals 500,000Low Temperature Hydrogen Cracking of Ni-base Alloys and Weld Metals 75,000Master Curve Fracture Toughness Implementation 300,000

NUCLEAR ENERGY RESEARCH INITIATIVE $4,569,821


Isomer Research: Energy Release Validation, Production and Applications 600,000 Incorporation of Integral Fuel Burnable Absorbers Boron and Gadolinium into

Zirconium-Alloy Fuel Clad Material 321,342 Design of Radiation-Tolerant Structural Alloys for Generation IV Nuclear Energy

Systems 641,875 Enhanced Thermal Conductivity Oxide Fuels 299,872


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OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY (continued)

FY 2002

NUCLEAR ENERGY RESEARCH INITIATIVE (continued)


Random Grain Boundary Network Connectivity as a Predictive Tool for Intergranular Stress-Corrosion Cracking 395,988

Fundamental Understanding of Crack Growth in Structural Components of Generation IV Supercritical Light Water Reactors 268,851

New Design Equations for Swelling and Irradiation Creep in Generation IV Reactors 458,552Oxidation of Zircaloy Fuel Cladding in Water-Cooked Nuclear Reactors 206,209Neutron and Beta/Gamma Radiolysis of Supercritical Water 477,403Innovative Approach to Establish Root Causes for Cracking in Aggressive Reactor

Environments 379,729Improving the Integrity of Coated Fuel Particles: Measurements of Constituent Properties

of SiC and ZrC, Effects of Irradiation, and Modeling 520,000

INTERNATIONAL NUCLEAR ENERGY RESEARCH INITIATIVE $825,000


Nano-Composited Steels for Nuclear Applications 475,000Ex-Vessel Melt Coolability and Concrete Interaction during a Severe Accident (MCCI Project) 350,000


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OFFICE OF NUCLEAR ENERGY, SCIENCE AND TECHNOLOGY

OFFICE OF SPACE AND DEFENSE POWER SYSTEMS

SPACE AND NATIONAL SECURITY PROGRAMS

Programs within the Office of Space and Defense Power Systems include the development and production of radioisotopepower systems (RPS) for both space and terrestrial applications and providing technical direction, planning, demonstrationand delivery of space fission power and propulsion systems.


284. MAINTAIN THE CAPABILITIES AND FACILITIESTO PRODUCE DOP-26 IRIDIUM ALLOY BLANKAND FOIL STOCK MATERIAL, MANUFACTURECLAD VENT SETS, AND MANAGE THE IRIDIUMINVENTORY$1,720,000DOE Contact: Robert Wiley (301) 903-2884ORNL Contacts: J. Peyton Moore (865) 574-8258

and Evan Ohriner (865) 574-8519

Iridium alloy, DOP-26 (i.e., Ir-0.3 wt% W with Th and Aladditions) is the fuel clad capsule material forradioisotope heat sources in space power systems forNASA missions. The production capabilities and facilitiesfor producing blank and foil stock material at ORNL aremaintained by continuing all production activities (powderprocessing, melting, extrusion, rolling, etc.) to supplylimited quantities of blank and foil for clad vent set (CVS)production maintenance activities. The CVS productionactivity produces flight quality CVSs for inventory andmaintains the production capabilities for future productioncampaigns. The iridium inventory for DOE is maintained,audited, and reported annually.

During FY 2002, 30 flight quality iridium alloy blanks and0.3 square meters of foil were produced and stored. Acommercial vendor was fully qualified for analysis ofiridium alloys using glow discharge mass spectrometry.All approvals were obtained, and the vendor is beingused routinely in this capacity. All documentation wasobtained for five flight quality CVSs produced in FY 2001,and these were shipped to Los Alamos NationalLaboratory. Ten additional flight quality clad vent setswere produced and shipped.

Keywords: Iridium Processing, Melting Extrusion, CladVent Sets

285. CARBON-BONDED CARBON FIBERINSULATION PRODUCTION, MAINTENANCE,MANUFACTURING PROCESS DEVELOPMENT,AND PRODUCT CHARACTERIZATION$439,000DOE Contact: Robert Wiley (301) 903-2884ORNL Contact: George Romanoski

(865) 574-4838

CBCF type thermal insulation is employed inradioisotopic General Purpose Heat Source (GPHS)module assemblies for use in RPSs for spaceapplications. This material was originally employed inGPHS-RTGs (Radioisotope Thermoelectric Generators)for Galileo/NASA (1989 launch) and Ulysses/NASA-European Space Agency (1990 lauch) missions. Materialproduced for the Cassini mission (1997 launch) wasmade with a replacement carbon fiber utilizing anoptimized process and process controls. Severalactivities required for CBCF production and certificationhad not been exercised for a few years. When attemptswere made to perform these activities, it was discoveredthat equipment and/or personnel changes had led to aloss of capabilities in some areas. The high-temperaturevacuum furnace used for outgassing all test samples wasrebuilt and requalified. Procedures for measuring ashcontent and thermal conductivity were rewritten and allapprovals were obtained. It was discovered that at leastone item of processing equipment was introducingimpurities into the CBCF, and modifications orreplacements were made as necessary.

Keywords: Insulation/Thermal, High TemperatureService, Carbon Fibers


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MATERIALS PROPERTIES, BEHAVIOR,CHARACTERISTICS OR TESTING

286. ALLOY DEVELOPMENT CHARACTERIZATION,MECHANICAL PROPERTY TESTING, ANDINSULATION OUTGASSING ASSESSMENT$1,105,000DOE Contact: Robert Wiley (301) 903-2884ORNL Contacts: Easo George (865) 574-5085,

J. Peyton Moore (865) 8258, Robert Swindemann (865) 574-5108

This activity provides the materials characterization,mechanical property information, and assessment ofmaterial behavior in specific applications to supportvarious RPS program needs. The characterization ofiridium alloy DOP-26 has identified the effect of variousimpurities on the alloy and on the manufacturing andservice reliability. An alternate iridium alloy (DOP-40)containing less thorium and the addition of cerium hasbeen developed and shown to have desirable properties.Mechanical property determinations are made on variousalloys after thermal aging to assess their suitability forlong-term terrestrial and space missions. Assessmentsare made of internal component materials for milliwattgenerator outgassing characteristics.

Significant progress was made in several areas duringFY 2002. Measurement of tensile properties on uniaxialsamples of Haynes 25 were completed. Thesemeasurements include both base metal and weldmentsamples aged for up to 12,000 hours. Nine creep rupturetests and two creep rate tests were completed on Haynes25. Results were within expectations for this alloy.Equipment was prepared for pressure burst testing ofHaynes 25 capsules, and eight weld verification capsuleswere received from Los Alamos National Laboratory.Installation of these eight into testing facilities wasinitiated. A model was developed for the ductility ofHaynes 25 as a function of exposure time at atemperature of 675 °C, and the influence of strain rate onductility was measured. Final reports were prepared ongrain growth in DOP-26 and DOP-40 iridium alloys.Attempts to define the influence of silicon on theproperties of DOP-26 were unsuccessful because ofproblems with the production of suitable test alloys. Areport was written on the insulator outgassing for themilliwatt generator, and tests were initiated to assessoutgassing of an electrical heater that will be used forsurrogate power in a sealed generator test.

Keywords: Iridium Alloys, Haynes 25, MaterialCharacterization, Thermal Aging

287. FABRICATION DEVELOPMENT ANDMATERIALS PRODUCTION FOR AMTECCONVERTERS$517,000DOE Contact: Robert Wiley (301) 903-2884ORNL Contacts: James King (865) 574-4807

The Advanced Radioisotope Power System (ARPS)Program has been developing AMTEC converters forpower conversion in generators for NASA spacemissions. ORNL has contributed to this program in theareas of refractory metal alloy production, welding andbrazing fabrication development and production ofconverters, measurement of total hemisphericalemittance and thermal conductivity, magnetron sputteringof electrode coatings on Beta”-alumina tubes, and studiesof oxidation kinetics.

In FY 2002, efforts continued to support the developmentof AMTEC cells. Additional arc-melted Mo-41%Rematerial was produced from powders, and plates androds were supplied to Advanced Modular PowerSystems, Inc. A promising alloy was identified forattaching Mo-41%Re to alumina insulators. This alloy hasa melting temperature of 1170 °C, and compatibilitytesting indicated that it is unaffected by exposure tosodium.

Keywords: Molybdenum, Rhenium, Welding andBrazing, AMTEC

OFFICE OF TECHNOLOGY AND INTERNATIONALCOOPERATION

NUCLEAR ENERGY PLANT OPTIMIZATION

The Nuclear Energy Plant Optimization (NEPO) Programis a U.S. Department of Energy (DOE) Program researchand development (R&D) program focused on theperformance of currently operating U.S. nuclear powerplants. The primary areas of focus for the R&D are plantaging and optimization of electrical production. Fundingfor the NEPO program comes from both the U.S. DOEand from private industry, with industry providing equal orgreater matching funds for each NEPO project.

288. STEAM GENERATOR (SG) NON-DESTRUCTIVEEXAMINATION (NDE) TEST MOCKUP FACILITY$260,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contact: J. Benson (650) 855-2146ANL Contact: T. Wei (630) 252-4688

Task: Develop a library of well characterized, laboratorygenerated axial, circumferential, inner diameter and outerdiameter cracks for use in assessing advanced NDEmethods being developed by DOE and EPRI.


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Results to Date:

- A glove box facility for NDE of tubes removed fromservice has been built.

- Inspection of six steam generator tube sectionsfrom the McGuire retired steam generators hasbeen completed.

- A team of experts analyzed X-Probe data acquiredfrom the steam generator mock-up.

- Inconel 600 tubing test samples containing stresscorrosion cracks have been prepared.

Keywords: Stress Corrosion Cracking, Non-DestructiveExamination, Steam Generator

289. ADVANCED EDDY-CURRENT INSPECTIONSYSTEM FOR DETECTION ANDCHARACTERIZATION OF DEFECTS IN STEAMGENERATOR TUBES$290,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contact: J. Benson (650) 855-2146ANL Contact: T. Wei (630) 252-4688

Task: Develop an advanced eddy-current inspectiontechnique and data analysis methodology for morereliable detection and accurate sizing of defects in steamgenerator tubes.

Results to date:

- Bobbin and Motor-Driven Rotating Pancake Coil(MRPC) data has been acquired from a test sectioncontaining three axial cracks of varying depths.Data has been acquired with and without interferingartifacts, such as tube supports and deposits.

- An effort was initiated on the development ofautomated data analysis algorithms to perform thefunction of anomaly detection and classification.

- Work on developing software to automaticallyanalyze eddy current data from array probes hasbegun.

Keywords: Stress Corrosion Cracking, Non-DestructiveExamination, Steam Generator, Eddy-Current

290. DEVELOP EMPIRICAL DATA TOCHARACTERIZE AGING DEGRADATION OFPOLYMERS USED IN ELECTRICAL CABLE$330,000DOE Contact: len W. Morris (301) 903-9527EPRI Contact: G. Toman (704) 547-6073SNL Contact: K. Gillen (505) 844-7494

Task: Compare natural aging to model predictions basedon accelerated aging; obtain naturally-aged samples;develop and confirm aging models; investigate bonded

jacket cable failure mechanisms; evaluate coaxialconnector backshell moisture intrusion and moisturedams.

Results to date:

- Several cable aging methods have been developedwhich are expected to have significant impact toresolution of cable aging issues.

- First proof-of-principle experiments using the newlyconceived wear-out approach show that it offersunique capabilities for predicting the remaininglifetimes of nuclear power plant cable materials.

- Bonded jacket insulation failure mechanismevaluation is complete. Two reports have beenissued: “Investigation of Bonded Jacket CableInsulation Failure Mechanisms” (1001002);“Investigation of Bonded Jacket Cable InsulationFailure Mechanisms: HELB Exposure Results”(1007635). The first report identified the agingfragility level for bonded jacket insulation withrespect to LOCA functionality. The second testshows that even overaged cable does not crack in aHELB exposure.

- Coaxial moisture intrusion study is complete. Thereport “Evaluation of Moisture Intrusion into CoaxialConnectors” (1001390) has been issued.

Keywords: Polymers, Aging, Irradiation, ElectricalInsulation

291. DEVELOP CONDITION MONITORING (CM)TECHNIQUES FOR ELECTRICAL CABLE$270,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contact: G. Toman (704) 547-6073SNL Contact: K. Gillen (505) 844-7494

Tasks: Activities under this project include thedevelopment of a basis with material-specific correlationbetween non-destructive examination (NDE) data anddestructive examination for localized (sample)inspections. Other activities include development ofelectrical NDE techniques capable of detecting incipientdefects along an entire cable run and NDE techniquessuitable for implementation at nuclear power plants. Inaddition, the project will develop distributed fiber optictemperature/radiation sensing methodology.

Results to date:

- Early results show that two new conditionsmonitoring (CM) techniques based on modulusprofiling and nuclear magnetic resonancemeasurements may be among the best CMtechniques available for determining cable conditionin existing nuclear power plants.


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- Cable aging assessment training aids have beendeveloped and are ready for use.

- A Beta version of the database software has beenissued to DOE. Formal issuance of the databasewill occur in December 2002.

- The low-voltage compendium report was issued inJanuary 2003.

- The medium voltage state of the industry report willbe issued in mid-2003.

Keywords: Aging, Irradiation, Electrical Insulation,Fiber Optics, Condition Monitoring

292. MECHANICAL BEHAVIOR OF IRRADIATEDSTRUCTURAL STAINLESS STEEL$465,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contact: H. T. Tang (650) 855-2012ANL Contact: D. L. Porter (208) 533-7659

Tasks: The project will determine the mechanicalbehavior of irradiated structural stainless steels underconditions of interest to Light Water Reactors (LWR) andtools to predict component life. The project will alsoassess the results of NDE examinations and guide thetiming of corrective actions. In addition, the project willdetermine the effect of irradiation history on theirradiation assisted stress corrosion behavior of multiplealloys of austenitic stainless steel and multiple heats ofselected materials in Pressurized Water Reactor (PWR)water.

Results to date:

- In-cell constant extension-rate testing (CERT)system has been developed at ANL. This system iscapable of simultaneous testing of two specimensin separate loading trains at different or identicaldisplacement rates (10-2 to 10-8 inch/sec) anddifferent or identical temperatures (up to 800degrees Celsius). The system can be used fortesting of various specimen designs, includingtensile, fracture mechanics, and point-bendspecimans.

- Mechanical testing performed showed saturation oftensile characteristics (yield stress, ultimate tensilestrength, uniform elongation and total elongation)achieved at 5 to 15 dpa with saturation levels higherfor the 316CW material than for 304SA material. Allfour (French and US) 316CW materials showedhomogeneity of the mechanical characteristics afterirradiation regardless of their initial characteristicsand no grain size effect was noticed. Four 304L SA

materials also showed homogeneous mechanicalcharacteristics after irradiation.

Keywords: Austenitic Stainless Steel, Irradiation,Mechanical Properties, Modeling, StressCorrosion Cracking

293. FATIGUE MANAGEMENT$400,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contacts: J. Carey (650) 855-2105

S. Rosinski (704) 547-6123, B. Carter (704) 547-6019

Tasks: Provide cost-effective methods of evaluating thecyclic life of nuclear components, including the effects ofreactor coolant environment. The methods will be basedon the safety margins of the American Society ofMechanical Engineer (ASME) code. The project will alsoprovide utilities with appropriate tools to manage fatigueeffects.

Results to date:

- Issued an Interim Thermal Fatigue Guideline toassist utility operators in taking a proactiveapproach in preventing unplanned leakage frompiping attached to reactor coolant systems.

- Developed an Interim model for a thermal fatiguescreening tool.

- Issued draft Guidelines for Addressing FatigueEnvironmental Effects for a Typical LicenseRenewal Application. This document provides amethod for considering reactor coolantenvironmental effects.

Keywords: Fatigue, ASME Code, EnvironmentalFatigue

294. ASSESSMENT OF AGING EFFECTS ONCOMPONENTS AND STRUCTURES FROMNUCLEAR POWER PLANTS$500,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contacts: J. Carey (650) 855-2105

S. Rosinski (704) 547-6123ORNL Contact: T. M. Rosseel (865) 574-5380PNNL Contact: S. K. Sundaram (509) 373-6665

Tasks: Obtain materials and components that have beenin service in operating reactors to be used for comparisonwith laboratory aged materials to validate models foraging effects and non-destructive examination methods.


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Results to date:

- The Big Rock Point Condition Assessment Project,which identified reactor and other plant componentswhich would be acceptable candidates for futureaging tests, is complete.

- A survey document has been prepared anddisseminated to utility and other industry materialsaging experts to identify key components whichshould be sampled for aging testing/modelvalidation.

- Materials and specific sections of reactor vesselinternals of decommissioned San Onofre NuclearGeneration Unit 1 (SONGS 1) have been identifiedfor harvesting. Samples from baffle plate, formerplate, and core barrel are being harvested.

Keywords: Aging, Non-Destructive Examinations,Modeling

295. IRRADIATION INDUCED SWELLING ANDSTRESS RELAXATION OF PWR REACTORCORE INTERNAL COMPONENTS$40,000DOE Contact: Glen W. Morris (301) 903-9527EPRI Contact: H. T. Tang (650) 855-2012

Tasks: Characterize irradiation-induced void swelling andstress relaxation related to degradation that could occurin operating reactors, and calibrate and extend the liquidmetal reactor-based swelling model for PWRapplications.

Results to date:

- A state-of-the-art review of void swelling andirradiation enhanced stress relaxation wasperformed. The review revealed small amounts ofvoid swelling (0.1-0.5 percent) in baffle boltsremoved from operating PWRs.

- To support the development of a method for in situmeasurement of void swelling, tests wereconducted using eddy current, Barkhausen noise,electro-potential and three ultrasonic (conventional,guided wave, and back-scattering) nondestructivetechniques. The materials tested were sets ofsurrogate material with electrical resistivity andYoung’s modulus altered by cold work or by use ofpowder metallurgy to determine the capability ofeach technique to measure 0.1 to 0.5% of voidswelling. The eddy current, ultrasonic, and electro-potential methods have the most potential for fieldapplications associated with the evaluation of voidswelling and irradiation enhanced stress relaxation.These techniques will be used to evaluate void

swelling attributes on irradiated materials, whichrepresents a new application for these evaluationtools.

Keywords: Irradiation-Induced Swelling, StressRelaxation

296. MITIGATION OF INITIATION AND GROWTH OFPWSCC IN ALLOY 600 AND 82/182 WELDMETALS$125,000DOE Contact: Glen W. Morris (301) 903-9527

Task: The task will develop methodology to address theinitiation and growth of primary water stress corrosioncracking in Alloy 600 and weld metals 182 and 82 forPWRs. This type of corrosion cracking has beenidentified in reactor pressure vessel welds for control roddrive mechanisms and in butt welds in 82 and 182 weldmetal in a reactor vessel hot leg nozzle.

Results to date: In bid preparation stage.

Keywords: Stress Corrosion Cracking, Welds, PWR

297. VALIDATION OF BWR FLUENCE MODELS ANDWELDABILITY OF INTERNALS$500,000DOE Contact: Glen W. Morris (301) 903-9527

Task: Material samples from BWR internal componentswill be obtained for use in benchmarking BWR fluencecalculation methodologies and to provide additional datafor determining weldability of BWR internal components.

Results to date: Contractors chosen; contracts beingfinalized.

Keywords: BWR, Welds, Fluence Calculation

298. LOW TEMPERATURE HYDROGEN CRACKINGOF Ni-BASED ALLOYS AND WELD METALS$75,000DOE Contact: Glen W. Morris (301) 903-9527

Task: Hydrogen based cracking may occur rapidly at lowtemperatures. The task will evaluate if low temperaturecrack growth is significant for weld metal 182 in PWRservice.

Results to date: Contractor chosen; contract beingfinalized.

Key Words: Hydrogen Cracking, Welds, PWR


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299. MASTER CURVE FRACTURE TOUGHNESSIMPLEMENTATION$300,000DOE Contact: Glen W. Morris (301) 903-9527

Task: The existing reactor pressure vessel (RPV) codes,standards and regulations use highly conservativemethods to determine the RPV material referencetemperature. This task will provide the basis forestablishing Master Curve fracture toughnessmethodology into codes, standards and regulations toallow excess conservatism to be removed fromcalculations to allow longer vessel life.

Results to date: Efforts to define and documentappropriate margins for application of the Master Curveapproach for RPV integrity assessment are underway. Aprocess flow chart outlining the necessary variables hasbeen generated.

Keywords: RPV, Master Curve, Fracture Toughness

NUCLEAR ENERGY RESEARCH INITIATIVE

Overall, the awarding of Nuclear Energy ResearchInitiative projects is expected to help preserve the nuclearscience and engineering infrastructure within our Nation’suniversities, laboratories and industries, as well asadvance the state of nuclear energy technology and tomaintain a worldwide competitive position. In regard tomaterials research, Nuclear Energy Research Initiativeprojects are performed in order to address issues relatedto the design and development of advanced nuclearreactors or to understand materials phenomena inexisting reactors.


300. ISOMER RESEARCH: ENERGY RELEASEVALIDATION, PRODUCTION ANDAPPLICATIONS$600,000DOE Contact: C. Thompson (301) 903-3918LLNL Contact: J. A. Becker (925) 422-9676

The goal of this applied nuclear isomer research programis the search for, discovery of, and practical application ofa new type of high energy density material (HEDM).Nuclear isomers could yield an energy source with aspecific energy as much as a hundred thousand times asgreat as that of chemical fuels. There would be enormouspayoffs to the Department of Energy and the country as awhole if such energy sources could be identified andapplied to a range of civilian applications.

Despite the potential payoff, efforts in applied isomerresearch have been rather limited and sporadic. There

has been basic research on nuclear isomers since theirdiscovery in 1935 with an occasional hint to tantalizeinterest in HEDM. In most cases, these hints were refutedby careful examination by other groups.

The isomer area is rich with possibilities. We haveprioritized several areas likely to be the most rewardingand fruitful for initial experimental and theoreticalinvestigation because these areas directly bear onimportant issues, such as the following:

- Can the energy stored in nuclear isomers bereleased on demand?

- Is the size of the atomic-nuclear mixing matrixelement large enough to be useful?

- Can we initiate quantal collective release ofisomeric energy from a crystal?

- What is the precise energy of the 3.5 eV level in229mTh?

The specific target experiments are:

- X-ray induced decay of 178m2Hf with a sensitivity 105

times recent work- NEET: A measurement of the atomic-nuclear

mixing matrix element in 189Os- Superradiance in 93mNb- TEEN: Nuclear isomer energy release in 178m2Hf- Energy and lifetime of the 229mTh isomeric level at

3.5 eV

Keywords: Isomer, NEET, TEEN, HEDM, High EnergyDensity Material

301. INCORPORATION OF INTEGRAL FUELBURNABLE ABSORBERS BORON ANDGADOLINIUM INTO ZIRCONIUM-ALLOY FUEL CLAD MATERIAL$321,342DOE Contact: C. Thompson (301) 903-3918University of Wisconsin Contact: K. Sridharan

(608) 263-4789 Long-lived fuels require the use of higher enrichments ofU-235 or other fissile materials. Such high levels of fissilematerial lead to excessive fuel activity at the beginning oflife. To counteract this excessive activity, integral fuelburnable absorbers (IFBA) are added to some rods in thefuel assembly. The three commonly used IFBA absorbersare gadolinium oxide and erbium oxide which are addedto the UO2 powder, and zirconium-diboride which isapplied as a coating on the UO2 pellets using plasmaspraying or chemical vapor deposition techniques. Theseoperations are performed as part o the fuelmanufacturing process in the fuel plants. due to thepotential for cross-contamination with fuel that does notcontain IFBA, these operations are performed in a facilitythat is physically separated from the main plant. These


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operations tend to be very costly because of their smallvolume and can add from 20 to 30% to the manufacturingcost of the fuel. Other manufacturing issues that impactcost are maintaining the correct levels of dosing and thereduction in fuel melting point due to gadolinium anderbiuim oxide additions.

The goal of the proposed research is to develop analternative approach that involves incorporation of boronor gadolinium into the fuel cladding material rather thanas a coating or additive to the fuel pellets. This paradigmshift will allow for the introduction of the IFBA in a non-nuclear regulated environment and will obviate thenecessity of additional handling and processing of thefuel pellets. This could represent significant cost savingsand potentially lead to greater reproducibility and controlof the burnable fuel in the early stages of the reactoroperation.

We propose the use of state-of-the-art ion-based surfaceengineering techniques to achieve this objective.Specifically, we propose the application of IBEST (IonBeam Surface Treatment) process being developed atSandia National Laboratory, which involves the deliveryof high-energy ion beam pulses onto the surface of atarget material. These pulses melt the top few microns ofthe target material’s surface. The melt zone thensolidifies rapidly at rates in excess of 109 K/sec due torapid heat extraction by the underlying substrate heatsink. This rapid solidification allows for surface alloyingwell in excess of the thermodynamically dictated solubilitylimits. This effect can be beneficially applied to theobjectives of the proposed research for incorporatingboron or gadolinium into the near-surface regions ofZircaloy-4 and Zirlo material used for fuel cladding.Several variants of this approach will be investigated withthe goal of optimizing the process parameters to achievethe desired structure, composition, and compositionalgradiant in the near-surface regions of the Zircaloy-4 andZirlo that, in addition to the incorporation of boron orgadolinium into the surface, also yield improvements insurface hardness and oxidation resistance.

Keywords: Boron, Gadolinium, Erbium, IBEST, IonBeam Surface Treatment, IFBA, IntegralFuel Burnable Absorbers, Nuclear FuelDevelopment

302. DESIGN OF RADIATION-TOLERANTSTRUCTURAL ALLOYS FOR GENERATION IVNUCLEAR ENERGYSYSTEMS$641,875DOE Contact: C. Thompson (301) 903-3918ANL Contact: T. Allen (208) 533-7760

The irradiation performance of structural materials willlikely be the limiting factor in successful nuclear energy

system development. The limits of the structural and fuelmaterials determine the performance of new nuclearenergy systems. Satisfactory performance in a nuclearenergy system is unusually demanding. In addition to thebest characteristics and performance of materials thathave been achieved in other advanced high temperatureenergy systems, nuclear energy systems requireexceptional performance under high fluence irradiation.Based on experience, materials not tailored for irradiationperformance generally experience profound changes invirtually all important engineering and physical propertiesbecause of fundamental changes in structure caused byradiation damage.

This project will develop and characterize the radiationperformance of materials with improved radiationresistance. Material classes will be chosen that areexpected to be critical in multiple Generation IVtechnologies. The material design strategies to be testedfall into three main categories: 1) alloying, by addingoversized elements to the matrix; 2) engineering grainboundaries; and 3) microstructural/nanostructural design,such as adding matrix precipitates.

The materials to be examined include both austenitic andferritic-martensitic steels, both classes of which areexpected to be key structural materials in manyGeneration IV concepts. The irradiation program willconsist of scoping studies using proton and heavy-ionirradiations of key alloys and tailored alloy conditioningand examination of materials irradiated in BOR-60 toconfirm charged particle results. Examinations willinclude microstructural characterization, mechanicalproperties evaluation using hardness and shear punch,and stress corrosion cracking.

Keywords: BOR-60, Irradiation, Microstructural,Nanonstructural, Nuclear

303. ENHANCE THERMAL CONDUCTIVITY OXIDEFUELS$299,872DOE Contact: C. Thompson (301) 903-3918Purdue University Contact: A. A. Solomon

(765) 494-5753

The objective of the proposed research is to produce anovel oxide fuel form with superior thermal conductivity.The resulting fuel will be applicable to existing light-waterreactors, especially with high burn-up, high-performancefuels. It is also expected that such fuel will providesuperior performance in advanced reactors that wouldotherwise be fueled with low-conductivity oxide fuels.

Keywords: Oxide Fuels, Light Water Reactor, ThermalConductivity


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304. RANDOM GRAIN BOUNDARY NETWORKCONNECTIVITY AS A PREDICTIVE TOOL FORINTERGRANULAR STRESS-CORROSION CRACKING$395,988DOE Contact: C. Thompson (301) 903-3918LLNL Contact: W. King, (925) 423-6547

In this work, we will develop methods to quantify theinterconnectivity of the random grain boundary network,measure the interconnectivity of a series of materialswhere the interconnectivity has been systematicallyaltered. We then perform property measurements on thematerials and compare their performance ranking withthe boundary network measurements, and characterizethe materials to correlate actual crack paths with themeasurements of the random grain boundary network.

With this data, we will then evaluate and improve themethods that have been chosen to describe the randomgrain boundary network. We will test the characterizationmethod by evaluating the interconnectivity of the randomgrain boundary network in a series of as-receivedmaterials, rank their expected performance, and comparethe results with property measurements.

The major accomplishments of this project are expectedto be 1) the determination that the random boundarynetwork connectivity (RBNC) is a major driver of IGSCCin low to medium stacking fault energy austenitic alloys,2) the development of a predictive tool for ranking IGSCCperformance of these alloys, and 3) the establishment ofthermochemical processing parameters to be applied inthe manufacture of IGSCC resistant materials. Theoutcome of the project will be identification of a mitigationstrategy for IGSCC in current LWR conditions that canthen enable the development of economically andoperationally competitive water-cooled advanced reactorsystems.

Keywords: Random Grain Boundary Network, RBNC,Intergranular Stress Corrosion Cracking

305. FUNDAMENTAL UNDERSTANDING OF CRACKGROWTH IN STRUCTURAL COMPONENTS OFGENERATION IV SUPERCRITICAL LIGHTWATER REACTORS$268,851DOE Contact: C. Thompson (301) 903-3918SRI International Contact: I. Balachov

(650) 859-3238

This work will contribute to the design of safe andeconomical Generation IV Supercritical Light WaterReactors (SCLWR) by providing a basis for selecting

structural materials to ensure functionality of in-vesselcomponents during the entire service life and estimatingthe lifetime of structural components under a variety ofnormal and offset operation conditions.

The objectives of this project are:

- Increase understanding of the fundamentals ofcrack growth in structural components ofGeneration IV SCLWR made of stainless steels andnickel-based alloys at supercritical temperatures.

- Provide tools for assessing the influence of theoperating conditions in power plants withsupercritical coolant temperatures on theelectrochemistry of different types of corrosionprocesses taking place in the coolant circuits ofsupercritical power plants.

- Measure material-specific parameters describingthe material’s susceptibility to stress corrosioncracking and other forms of environmentallyassisted degradation of structural materials atsupercritical coolant conditions.

- Use these measurements to interpret the rate-limiting processes in the corrosion phenomena andas input data for lifetime analysis.

- Use the SRI-developed FRASTA (Fracture surfacetopography analysis) technique to obtaininformation on crack nucleation times and crackgrowth rates via analysis of conjugate fracturesurfaces. Identify candidate remedial actions bywhich the susceptibility to stress corrosion crackingcan be decreased

A unique combination of two advanced techniques forstudying material reliability will be used. ControlledDistance Electrochemistry (CDE) will allow us todetermine in relatively short experiments a measurablematerial parameter that describes the transport of ions orionic defects in the oxide films and that will be correlatedwith the susceptibility to cracking, using fracture surfacetopography analysis (FRASTA) to reconstruct theevolution of crack initiation and growth.

Keywords: Crack Growth, Corrosion, Fracture SurfaceTopography Analysis, Controlled DistanceElectrochemistry

306. NEW DESIGN EQUATIONS FOR SWELLINGAND IRRADIATION CREEP IN GENERATION IVREACTORS$458,552DOE Contact: C. Thompson (301) 903-3918LLNL Contact: W. G. Wolfer (925) 423-1501

Our understanding of void swelling and irradiation creephas been challenged recently by new discoveries thatnecessitate the development of a more comprehensivemodeling of microstructural evolution under irradiation,


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and a derivation of new constitutive equations for swellingand irradiation creep different from those in the past. Themicrostructural foundations of these new constitutive lawswill provide design equations for swelling and irradiationcreep which can be confidently extrapolated and appliedto Generation IV reactor concepts. Some of these newdiscoveries include the commencement of void swellingat lower doses with lower dose rates; the occurrence ofvoid swelling in LWRs and at temperatures lower thanpreviously believed possible; the observations of highconcentrations of hydrogen in LWR components whichexhibit void swelling, implicating hydrogen in addition tohelium as a nucleating agent for voids; and the findingthat irradiation creep is first enhanced when void swellingcommences, but then declines and nearly vanishes as asteady-state swelling rate is approached. These newdiscoveries are the result of having constructed andanalyzed an extensive database from many differentirradiation experiments. The proposed comprehensivemodeling of void nucleation and evolution of themicrostructure is now made possible with the dramaticadvancements in scientific computing afforded by theASCI (Advanced Strategic Computing Initiative).

We are proposing to develop the theoretical models andthe computer simulation codes to predict the evolution ofthe microstructure in structural materials exposed toneutron irradiations and to the chemical and thermo-mechanical environments in Generation IV reactors aswell as existing reactors. In addition, we propose todevelop also compact, macroscopic constitutiveequations for swelling and irradiation creep that can beused in reactor design and performance evaluation.

We are pursuing a dual approach in this project, whichconsists of two coupled feedback loops of modeldevelopment and model verification. One feedback loopencompasses the microstructural models and TEM datafrom irradiated samples. The other feedback loop dealswith macroscopic constitutive laws for swelling andirradiation creep and their calibration with data fromdensity measurements and creep strains. The two loopsare connected by the derivation of the functional form ofthe constitutive laws from the microstructural models. Theduel validation at the microscopic and the macroscopiclevel will greatly enhance the consistency and the validityof the predictions when the performance parameters ofGeneration IV reactors are outside the range for existingreactors.

Keywords: Microstructure, Macrostructure, VoidSwelling, Irradiation Creep, Generation IV,LWR

307. OXIDATION OF ZIRCALOY FUEL CLADDING INWATER-COOKED NUCLEAR REACTORS$206,209DOE Contact: C. Thompson (301) 903-3918Pennsylvania State University Contact:

D. MacDonald (814) 863-7772

With the development of higher burn-up fuels for nuclearpower reactors, much greater demands are being placedon the performance of the Zircaloy fuel sheaths. Theprinciple threat to the integrity of the sheath isoxidation/corrosion and hydriding, leading to more-or-lessuniform thinning and, in some instances, to localizedcorrosion in the form of nodular attack and/or hydriding.Failure leads to the release of fission products into thecoolant, which in turn contributes to the man-REM costsof operating the system. Extensive fuel failures mayrequire shutdown, which results in the unit beingunavailable for normal operation. Thus, strongoperational and economic reasons exist for enhancingfuel reliability. The principle goal of the proposed work isto develop sophisticated physico-electrochemical modelsfor the corrosion of Zircaloy fuel sheaths that can be usedby reactor operators to actively manage the accumulationof damage and hence to minimize the risk of fuel claddingfailure in operating reactors.

The proposed research will represent a major departurefrom work being carried out elsewhere, in that it will:

- Incorporate the Point Defect Model (PDM) in placeof the diffusion models to describe oxide andhydride growth.

- Incorporate the cathodic reactions that occur at thefuel caldding/coolant interfacing including the role ofintermetallic precipitates in the film as catalytic sitesfor these reactions.

- Incorporate an advanced coolant radiolysis modelfor estimating the concentrations of electroactivespecies (oxygen, hydrogen peroxide, hydrogen,etc.) at the cladding surface, as a function of thechemistry of the coolant (pH, [Li], [B], [H2]) and theoperating conditions of the reactor.

- Include the mechanisms (cation vacancycondensation) for passivity breakdown as a meansof describing the onset of nodular attack.

- Develop a model based upon the generation andannihilation of point defects (oxygen vacancies,cation vacancies, and zirconium interstitials) at theZircaloy/zirconia and zirconia/solution interfaces todescribe the generation of stress in the interphasialregion.

- Incorporate a model for the concentration of solutesinto porous deposits (CRUD) on the fuel underboiling (BWRs) or nucleate boiling (PWRs)conditions, in order to more accurately describe theenvironment that is in contact with the Zircaloysurface.


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- Integrate the damage over the operating history ofthe reactor, including start-ups, shut downs, andvariable power operation.

- Explore the electronic structure and measure kineticparameters for ZrO2 film growth on Zircaloy underaccurately simulated reactor operating conditions.Film growth will be followed in situ byelectrochemical impedence spectroscopy(EIS)/capacitance measurements, whereas theelectronic structure will be determined by usingMott-Schottky analysis.

- Measure kinetic parameters (exchange currentdensities and transfer coefficients) for the reductionof oxygen and the oxidation of hydrogen on Zircaloyunder prototypical reactor operating conditions,these data being required to accurately model thecathodic processes that occur on the claddingsurface.

The output of this project will be a more comprehensiveunderstanding of the oxidation and hydriding of Zircaloyfuel cladding in reactor coolant environments, withparticular emphasis on linkage between the plantoperating parameters and the damage incurred due tooxidation and hydriding. Additionally, the project will yielda set of models and codes that will be made available tothe nuclear power industry for managing theaccumulation of corrosion damage to reactor fuelcladding as a function of the coolant chemistry andreactor operating conditions and history.

Finally, the development of the models and codesoutlined in this proposal could greatly aid in thedevelopment of Generation IV reactors, by exploringwater chemistry, materials/environment compatibility, andfuel design options that would minimize corrosion(oxidation and hydriding) damage to fuel cladding underspecified operating regimes.

Keywords: Electrochemical Impedence Spectroscopy,EIS, Hydriding, Zircaloy, Oxidation,Corrosion, Point Model Defect, PMD

308. NEUTRON AND BETA/GAMMA RADIOLYSIS OFSUPERCRITICAL WATER$477,403DOE Contact: C. Thompson (301) 903-3918ANL Contact: D. M. Bartels (630) 252-3485

Commercial nuclear reactors provide a source of heat,used to drive a “heat engine” (turbine) to createelectricity. A fundamental result of Thermodynamicsshows that the higher the temperature at which any heatengine is operated, the greater its efficiency.Consequently, one obvious way to increase the operatingefficiency and profitability for future nuclear power plantsis to heat the water of the primary cooling loop to highertemperatures. Current pressurized water reactors run at

roughly 300 °C and 100 atm pressure. Designs underconsideration would operate at 450 °C and 250 atm, i.e.,well beyond the critical point of water. This would improvethe thermodynamic efficiency by about 30%. The majorunanswered questions are: What changes will occur inthe radiation-induced chemistry in water as thetemperature and pressure are raised beyond the criticalpoint, and what does this imply for the limiting corrosionprocesses in the materials of the primary cooling loop?

The cooling water of any water-cooled reactor undergoesradiolytic decomposition, induced by gamma, fast-electron and neutron radiation in the reactor cores.Unless mitigating steps are taken, oxidizing speciesproduced by the coolant radiolysis can promoteintergranular stress-corrosion cracking and irradiation-assisted stress-corrosion cracking of iron- and nickel-based alloys. These will alter corrosion rates of iron- andnickel-based alloys, and zirconium alloys in reactors. Onecommonly used remedial measure to limit corrosion byoxidizing species is to add hydrogen in sufficient quantityto chemically reduce transient radiolytic primary oxidizingspecies (OH, H2O2, H2O/O2), thereby stopping theformation of oxidizing products (H2O2 and O2). It is stillunclear whether this will be effective at the highertemperatures proposed for future reactors. While anearlier NERI project has investigated some of the mostimportant radiation chemistry in supercritical water, thereis no information at all on the effect of neutron radiolysis,which is the main source of the troublesome oxidizingspecies.

The collaboration proposed here is ideally suited todiscover most of the fundamental information necessaryfor a predictive model of radiation-induced chemistry in asupercritical water reactor core. Electron pulse radiolysiscoupled with transient absorption spectroscopy is themethod of choice for measuring kinetics of radiation-induced species, and also product yields for fast electronand gamma radiation. The Argonne Chemistry Divisionlinac is capable of producing 20 MeV electron pulses of30 picoseconds duration, and the principal investigatorsat Argonne have extensive experience in measuringtransients on a nanosecond and sub-nanosecondtimescale. The University of Wisconsin Nuclear ReactorFacility is a very convenient source of neutron radiationthat can be exploited for radiolysis experiments fromroom temperature to 500°C. The combined capabilitieswill make it possible to create a quantitative model forwater radiolysis in both current PWR systems andsupercritical water-cooled plants in the future.

Keywords: Radiolysis, Radiolytic Decomposition,Supercritical Water, Intergranular StressCorrosion Cracking, IGSCC


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309. INNOVATIVE APPROACH TO ESTABLISH ROOTCAUSES FOR CRACKING IN AGGRESSIVEREACTOR ENVIRONMENTS$379,729DOE Contact: C. Thompson (301) 903-3918PNNL Contact: S. M. Bruemmer, (888) 375-7665

The successful development of Generation IV nuclearpower systems must address and mitigate severalmaterials degradation issues now strongly impactingexisting light water reactors (LWRs) after very longperiods of operation. In addition, the more aggressiveradiation and environmental exposures envisioned forvarious advanced reactor concepts will require materialswith improved high-temperature properties andresistance to cracking. Although previous fast reactor andfusion device programs have focused on thedevelopment of improved structural materials for theirrelevant conditions, no comparable effort has beendirected toward the conditions unique to water-cooledfission reactors since the inception of nuclear-poweredpropulsion units for submarines. The paramount issueimpacting both LWR economics and safety has beencorrosion and stress corrosion cracking in high-temperature water. These degradation processes havecontinued to limit performance as the industry haschanged operating parameters and materials.Mechanistic understanding and non-traditionalapproaches are necessary to create durable corrosion-resistant alloys and establish the foundation for advancedreactor designs. Less down time and longer componentlifetimes are the drivers motivating this research for bothGeneration III and IV nuclear-power systems.

Proposed research will focus on the characterization ofcritical Fe- and Ni-based stainless alloys tested underwell-controlled conditions where in-service complexitiescan be minimized. Quantitative assessment of crack-growth rates will be used to isolate effects of keyvariables, while high-resolution analytical transmissionelectron microscopy will provide mechanistic insights byinterrogating crack-tip corrosion/oxidation reactions andcrack-tip structures at near atomic dimensions. Reactionsat buried interfaces, not accessible by conventionalapproaches, will be systematically interrogated for thefirst time. Novel mechanistic “fingerprinting” of crack-tipstructures tied to thermodynamic and kinetic modeling ofcrack-tip processes will be used to isolate causes ofenvironmental cracking. Comparisons will be made withresults on failed components removed from LWR service(funded separately by industry collaborators).

The proposed research strategy capitalizes on uniquenational laboratory, industry and university capabilities togenerate basic materials and corrosion science resultswith immediate impact to next-generation nuclear powersystems. This proposed work will be integrated withexisting NERI projects, with fundamental research funded

by the DOE Office of Basic Energy Sciences and withfocused U.S. and international projects dealing withcurrent LWR degradation issues. This leveragedapproach will facilitate the revolutionary advancesenvisioned in NERI by creating a multi-faceted effortcombining the basic and applied science necessary todrive mechanistic understanding and promotedevelopment of next-generation materials that meetadvanced reactor performance goals.

Keywords: Crack-Tip, Advanced Nuclear Reactor,LWR, Stress Corrosion, Crack Growth

310. IMPROVING THE INTEGRITY OF COATED FUELPARTICLES: MEASUREMENTS OFCONSTITUENT PROPERTIES OF SiC AND ZrC,EFFECTS OF RADIATION, AND MODELLING$520,000DOE Contact: C. Thompson (301) 903-3918ORNL Contact: L. L. Snead (865) 574-9942

The SiC layer integrity in the TRISO-coated gas-reactorfuel particle is critical to the performance, allowed burn-up, hence intrinsic efficiency of high temperature gas-cooled reactors. While there has been significantdevelopmental work on manufacturing the fuel particles,detailed understanding of what effects the complex in-service stress state combined with realistic materialsproperty data under irradiation has on fuel particlesurvival is not adequately understood. Furthermore,zirconium carbide, which has been proposed as a higher-temperature replacement for SiC, has virtually noexperimental database on the effects of irradiation onthermo-mechanical properties. The basic assertionbehind this proposal is that significant need exists fordetailed fuel particle modeling including realistic,experimentally derived data on fuel particle constituentmaterials in the non-irradiated and irradiated condition.To perform this work will require advances in modeling,along with technique development for measurement ofmaterials properties at the small scale of the fuel particle.

Proposed elements of work:

Modeling Work. In recent years, a collaboration has beenestablished between INEEL and MIT looking into finiteelement and other methods of modeling the stress stateof fuel pellets. This has been carried to the point where itis being limited by the lack of realistic material propertyinput. Specific input on SiC statistical distribution ofstrength, creep and swelling are poorly described in theliterature. Thermo-mechanical properties of pyrolytic ZrCare also very limited. These new data will be generatedand applied in model spherical and cylindrical geometry.The objective of this work is to use the new data to betterdescribe the stress state of the TRISO particle underirradiation and to give a direct comparison of the integrity


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of SiC-v-ZrC for this application. Potential failure duringpellet processing will also be addressed.

Technique Development for Measurement of ConstituentProperties. To this point, techniques to study the integrityof fuel particles have been relatively rudimentary,consisting of compression tests (crush or c-ring) of theparticle or bare SiC overcoat. The objective of thiselement is to apply state-of-the-art techniques and todevelop new techniques specifically for application to theTRISO system to generate realistic data for the modeling.These techniques would then become available for thegas-cooled reactor fuels development community.Specific tools will be developed to measure strengththrough internal pressurization, elastic modulus on thescale of the TRISO particle, creep relaxation, andPyC/SiC interfacial properties.

Irradiation Materials Property Information. An irradiationprogram will be coupled with the technique developmentprogram to generate mechanical property informationneeded for modeling input. Irradiation program willinclude model, non-fueled cylindrical and sphericalTRISO structures, and spherical TRISO containinghelium producing boron carbide.

Updated Materials Data Handbook for TRISO fuels. Aspart of this effort, a materials property handbook will bedeveloped. This handbook will include pertinent physicalproperty information on all constituent materials of coatedparticle fuel. Sources of information will be both takenfrom the open nuclear materials literature, reports dealingwith HTGR’s (e.g., CEGA-002820, Rev 1), andinformation developed as part of this proposal. Thismaterial will then be available to the larger fuelscommunity.

Keywords: TRISO, SiC, Fuel Particles, Irradiation

INTERNATIONAL NUCLEAR ENERGY RESEARCHINITIATIVE

The I-NERI sponsors innovative scientific andengineering R&D, in bilateral cooperation withparticipating countries, to address the key issuesaffecting the future of nuclear energy and its globaldeployment. The goal of I-NERI is to develop advancedtechnologies to improve cost performance, enhancesafety, and increase proliferation resistance of futurenuclear energy systems. The primary objectives of the I-NERI Program in accomplishing this goal are to:

- Develop advanced concepts and scientificbreakthroughs in nuclear energy and reactortechnology to address and overcome the principaltechnical and scientific obstacles to the expandeduse of nuclear energy worldwide

- Promote bilateral collaboration with internationalagencies and research organizations to improvedevelopment of nuclear energy

- Promote and maintain the nuclear science andengineering infrastructure to meet future technicalchallenges


311. NANO-COMPOSITED STEELS FOR NUCLEARAPPLICATIONS$475,000DOE Contact: S. Schuppner (301) 903-1652ORNL Contact: Roger E. Stoller (865) 576-7886

The successful development of advanced nucleartechnologies embodied in the overall concept ofGeneration IV reactors will provide major challenges tothe field of materials science. An underlying themecommon to all systems under consideration is the criticalimportance of developing fuel cladding and structuralmaterials that outperform the best of the materialscurrently code-qualified for in-core applications. Forexample, the development of alloys with greatly improvedcreep strength, fracture resistance, and oxidationresistance combined with a high degree of tolerance forradiation damage would enable systems to be designedwith higher operating temperatures and extendedcomponent lifetimes.

Alloy development efforts in Japan, Europe, and the U.S.have shown that nano-composited versions of the Fe-8Crferritic-martensitic and Fe-13Cr ferritic steels have thepotential for developing into a new class of creep- andoxidation-resistant steels with outstanding swellingresistance that could be deployed in Generation IVreactor systems. Work is continuing at various institutionsto address issues such as anisotropic properties, thermalembrittlement, strength loss associated withmicrostructural instabilities, and compatibility with liquidand gaseous environments.

This collaborative proposal seeks to develop a scientificknowledge base on the fundamental deformation andfracture characteristics of several carefully selectedrepresentative nano-composited steels strengthened byfine scale oxide particles or atom clusters rich in yttria,titanium, and oxygen. This information will be combinedwith a study of the effects of neutron irradiation onmicrostructural stability and mechanical behavior toprovide a solid foundation for further development ofthese innovative materials for nuclear applications.

Miniaturized tensile, creep, and fracture testingtechniques will be used, coupled with microstructuralcharacterization to define a limited set of promisingcomposition/microstructures for neutron irradiation


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studies. Nano-scale structural characterization will becarried out to provide input to microstructure-propertymodeling activities. Extensive use of Ashby deformationand fracture mapping will be made to characterize thedominent regimes of deformation and fracture processes.A preliminary assessment will be made of the radiationresponse of a limited number of promisingcomposition/microstructures; irradiations will be carriedout using experimental facilities at Phenix, HFIR, orJOYO. The impact of neutron irradiation on thedeformation and fracture regimes will be mapped.Relationships between the radiation-modifiedmicrostructure and the dominant modes of deformationand fracture will be modeled. This information will beintegrated with that obtained from other programs todevelop a thorough evaluation of the potential of thesematerials for expanding the operating temperature limitsof fission reactor systems.

Keywords: Microstructure, Irradiation, Ferritic,Martensitic, Steel, Embrittlement

312. EX-VESSEL MELT COOLABILITY ANDCONCRETE INTERACTION DURING A SEVEREACCIDENT (MCCI PROJECT)$350,000DOE Contact: S. Schuppner (301) 903-1652ANL Contacts: J. L. Binder (630) 252-7265 and

M. T. Farmer (630) 252-4539

The MCCI program is a collaborative project between theReactor Analysis and Engineering (RAE) Division ofArgonne National Laboratory, the U.S. NuclearRegulatory Commission, and a consortium of teninternational participants represented by the NuclearEnergy Agency (NEA) of the Organization for EconomicCooperation and Development. U.S. NRC is theOperating Agent for the program.

Although extensive research has been conducted overthe last several years in the areas of melt coolability andcore-concrete interaction, two important issues warrantfurther investigation. The first issue concerns theeffectiveness of water in terminating a core-concreteinteraction by flooding the interacting masses fromabove, thereby affecting a quench of the molten coredebris and rendering it permanently coolable. The secondissue concerns long-term two-dimensional ablation by aprototypic core oxide melt. The goal of the MCCIresearch program is to conduct reactor materialexperiments and associated analysis to achieve thefollowing two technical objectives: 1) Resolution of theex-vessel debris coolability issue through a programwhich focuses on providing both confirmatory evidenceand test data for the coolability mechanisms identified inMACE integral effects tests; and 2) Address remaininguncertainties related to long-term two-dimensional core-concrete interaction under both wet and dry cavity

conditions. Achievement of these two main objectives willlead to improved accident management guidelines forexisting plants and also better containment designs forfuture plants.

Keywords: Melt Coolability, Core-Concrete Interaction

National Nuclear Security Administration

1This excludes $51.7 million for the cost of irradiation testing in the Advanced Test Reactor (ATR).

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FY 2002

NATIONAL NUCLEAR SECURITY ADMINISTRATION - GRAND TOTAL $114,492,000

OFFICE OF NAVAL REACTORS $79,200,0001

OFFICE OF DEFENSE PROGRAMS $20,069,000

THE WEAPONS RESEARCH, DEVELOPMENT AND TEST PROGRAM $20,069,000

SANDIA NATIONAL LABORATORIES $14,486,000


Materials Synthesis 1,042,000 Metal Processing Science 1,342,000 LIGA Processing 1,058,000 Microstructural and Continuum Evolution Modeling of Sintering 275,000 Biocompatible Self-Assembly of Nano-Materials for Bio-MEMS and Insect Reconnaissance 350,000 Understanding Metal Vaporization from Transient High Fluence Laser Irradiation 85,000 Science Based Processing of Field-Structured Composites 100,000 Design, Synthesis, and Characterization of Soft Matter Nanolayer Superlattices 300,000 Photo-Control of Nano-Interactions in Microsystems 275,000 Electrochemically Deposited Alloys with Tailored Nanostructures for LIGA Micromachines 340,000 Next-Generation Output-Based Process Control: an Integration of Modeling,

Sensors, and Intelligent Data Analysis 257,000 Solution-Based Nanoengineering of Materials 320,000 All-Ceramic Thin-Film Battery 310,000


Materials Performance 950,000 High Pressure and Shock Physics 250,000 Aging of Organic Materials 485,000 Corrosion Science and Metal Degradation 135,000 Surface and Interface Reliability 529,000 Nanomechanics 250,000 Micro-Mechanical Behavior and Tribology 200,000 Magnetic-Field Effects on Vacuum-Arc Plasmas 225,000 First-Principles Determination of Dislocation Properties 170,000 Dynamics of Metal/Ceramic Interfaces 160,000 In-Situ Characterization of Soft Solution Processes for Nanoscale Growth 100,000 Determination of Critical Length Scales for Corrosion Processes Using

Microelectroanalytical Techniques 160,000 Exploration of New Multivariate Spectral Calibration Algorithms 152,000 Nanostructured Materials for Directed Transport of Excitation Energy 300,000 The Effects of Varying Humidity on Copper Sulfide Film Formation 200,000 Mechanisms of Dislocation-Grain Boundary Interaction 264,000 Physical Basis for Interfacial Traction—Separation Models 297,000 Making the Connection Between Microstructure and Mechanics 257,000 Diagnostics for Joining Solidification/microstructural Simulations 327,000 Effects of Microstructural Variables on the Shock Wave Response of PZT 95/5 321,000


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NATIONAL NUCLEAR SECURITY ADMINISTRATION (continued)

FY 2002

OFFICE OF DEFENSE PROGRAMS (continued)

THE WEAPONS RESEARCH, DEVELOPMENT AND TEST PROGRAM (continued)

SANDIA NATIONAL LABORATORIES (continued)


The Basics of Aqueous Nanofluidics: "Interphase" Structure and Surface Forces 300,000Modeling Local Chemistry in the Presence of Collective Phenomena 170,000


Assuring Ultra-Clean Environments in Micro-System Packages: Irreversible and Reversible Getters 365,000

Mechanics and Tribology of MEMS Materials 270,000LIGA Microsystems Aging: Evaluation and Mitigation 360,000


Advanced Analytical Technology Project 735,000Information Extraction 500,000

LOS ALAMOS NATIONAL LABORATORY $15,223,000

Enhanced Surveillance Campaign 15,223,000

LAWRENCE LIVERMORE NATIONAL LABORATORY $5,583,000


Engineered Nanostructure Laminates 2,750,000


AFM Investigations of Biomineralization 113,000Polyimide Coating Technology for ICF Targets 1,400,000Beryllium Ablator Coatings for NIF Targets 400,000Using Dip-Pen Nanolithography to Order Proteins and Colloids at Surfaces 420,000Plasma Polymer Coating Technology for ICF Targets 500,000


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The mission of the National Nuclear Security Administration is:

- To enhance United States national security through the military application of nuclear energy.

- To maintain and enhance the safety, reliability and performance of the U.S. nuclear weapons stockpile, includingthe ability to design, produce and test, in order to meet national security requirements.

- To provide the U.S. Navy with safe, militarily effective nuclear propulsion plants and to ensure the safe andreliable operation of those plants.

- To provide international nuclear safety and nonproliferation.

- To reduce global danger from weapons of mass destruction.

- To support U.S. leadership in science and technology.

OFFICE OF NAVAL REACTORS

The Deputy Administrator for Naval Reactors within theNational Nuclear Security Administration is responsiblefor conducting requirements under Section 309(a) of theDepartment of Energy Organization Act which assignscivilian power reactor programs and all DOE navalnuclear propulsion functions. Executive Order 12344, asset forth in Public Law 106-65, stipulates responsibilitiesand authority of the Naval Nuclear Propulsion Program,of which the Deputy Administrator for Naval Reactors is apart.

The materials program supports the development andoperation of improved and longer life reactors andpressurized water reactor plants for naval nuclear propul-sion.

The objective of the materials program is to develop andapply, in operating service, materials capable of useunder the high power density and long life conditionsrequired of naval ship propulsion systems. This workincludes irradiation testing of reactor fuel, poison, andcladding materials in the Advanced Test Reactor at theIdaho National Engineering Laboratory. This testing andassociated examination and design analysis demon-strates the performance characteristics of existingmaterials as well as defining the operating limits for newmaterials.

Corrosion, mechanical property, and wear testing is alsoconducted on reactor plant structural materials underboth primary reactor and secondary steam plantconditions to confirm the acceptability of these materialsfor the ship life. This testing is conducted primarily at twoGovernment laboratories—Bettis Atomic PowerLaboratory in Pittsburgh and Knolls Atomic PowerLaboratory in Schenectady, New York.

One result of the work on reactor plant structural materialis the issuance of specifications defining the processingand final product requirements for materials used in navalpropulsion plants. These specifications also cover theareas of welding and nondestructive testing.

Funding for this materials program is incorporated innaval projects jointly funded by the Department ofDefense and the Department of Energy. This fundingamounts to approximately $130.9 million in FY2002.Approximately $51.7 million represents the cost forirradiation testing in the Advanced Test Reactor.The Naval Reactors contact is David I. Curtis,(202) 781-6141.

OFFICE OF DEFENSE PROGRAMS

The Deputy Administrator for Defense Programs withinthe National Nuclear Security Administration isresponsible for carrying out national security objectivesestablished by the President for nuclear weapons andassisting in reducing the global nuclear danger byplanning for, maintaining and enhancing the safety,reliability and performance of the U.S. stockpile ofnuclear weapons and associated materials, capabilitiesand technologies in a safe, environmentally sound, andcost-effective manner.


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THE WEAPONS RESEARCH, DEVELOPMENT ANDTEST PROGRAM

SANDIA NATIONAL LABORATORIES


313. MATERIALS SYNTHESIS$1,042,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: B.G. Potter (505) 844-9919 andWilliam R. Even, Jr. (925) 294-3217

This project explores innovative synthesis strategies tocreate materials to meet specified performancerequirements for established and anticipated applicationsin the enduring stockpile. The overall goal is to establishmaterials-based options for both passive and activefunctions critical to the successful execution of bothconventional and micro-scale systems. Areas of currentemphasis include new approaches for removableencapsulants, foams and adhesives, new polymericmaterials for MEMS encapsulants, and the control ofmaterial structure from the nano- to the meso-scale toprovide options for advanced chemical and physical statesensing, filtering and gettering, and photon/radiationmanipulation.

Keywords: Encapsulants, Foams, Sensing, Gettering,Polymers

314. METAL PROCESSING SCIENCE$1,342,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: Mark F. Smith (505) 845-3256 andCharles H. Cadden (925) 294-3650

The primary focus of this activity is to develop andintegrate fundamental understanding, scientific methods,and process modeling to create a knowledge base andenhanced tools for metal manufacturing processes (e.g.,welding, active brazing, soldering, thermal spray, melting,and casting) used in the production of non-nuclearcomponents. Activities in this area include thedevelopment of innovative new techniques to make in-situ measurements of fundamental properties necessaryto better understand process physics and to validatecomputer process models. We are also studying theeffect of hydrogen on metals, because this issue is criticalfor nuclear weapon systems. The ultimate goal of thiseffort is to establish a robust capability for guidingmanufacturing process parameter selection andpredicting the ultimate performance of manufacturedparts.

Keywords: Welding, Brazing, Soldering, ThermalSpray, Hydrogen Effects

315. LIGA PROCESSING$1,058,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: Jill M. Hruby (925) 294-2596 and H.Eliot Fang (505) 844-4526

LIGA is a microfabrication technique that uses X-raylithography and electroplating to create metal microparts.LIGA microparts offer a way to improve manufacturing,decrease tolerances, improve performance, enable newmeasurement schemes, and reduce the weight and sizeof weapon components and flight test assemblies. Thereis a continuing effort in both experimental andcomputational approaches to understanding andextending LIGA processing in order to enable the widestvariety of potential weapon applications with the lowestpossible risk. The efforts are aimed at evaluation of thefundamentals of the lithography as well as theelectroplating processes, and the relation between theprocesses and the structure and property of thefabricated parts.

Keywords: Microfabrication, Lithography,Electroplating, Metal, X-ray

316. MICROSTRUCTURAL AND CONTINUUMEVOLUTION MODELING OF SINTERING$275,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Veena Tikare (505) 844-1306

All ceramics and powder metals, including the ceramicscomponents that Sandia uses in critical weaponscomponents, are sintered, which is one of the mostcritical processing steps during ceramic manufacturing.Microstructural evolution, macroscopic shrinkage, andshape distortions during sintering will control theengineering performance of the resulting ceramiccomponent. Yet, modeling and prediction of sinteringbehavior is in its infancy, lagging far behind the othermanufacturing models. This project is developing a set ofcomputational tools that will enable us to understand,predict, and control microstructural evolution andmacroscopic dimensional changes during sintering.Previous research efforts on sintering modeling havefailed because they treat some limited aspect of sintering,either on the microstructural or macroscopic continuumscale. This novel modeling method can treat themicrostructural evolution of thousands of powder particlesduring sintering and integrate the results into continuummodels to predict the overall shrinkage and shapedistortions in a sintering component. An equally importantresult of this work will be a fundamental advancement inthe understanding of sintering science.

Keywords: Sintering, Ceramic Manufacturing,Microstructural Evolution, ManufacturingModels


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317. BIOCOMPATIBLE SELF-ASSEMBLY OF NANO-MATERIALS FOR BIO-MEMS AND INSECTRECONNAISSANCE$350,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: C. Jeffrey Brinker (505) 272-7627

Cell-based sensors have the potential to integrate, withina very small volume, recognition, amplification, andtransduction properties. Unfortunately most cell-basedsensor designs require external fluidic systems andelectronics to ensure cell viability and addressability,making them impractical as miniaturized sensorplatforms. The goal of our project is the development ofbiocompatible self-assembly procedures enabling theimmobilization of genetically engineered cells in acompact, self-sustaining, remotely addressable sensorplatform useful for covert insect reconnaissancemissions. Key to this concept is patterned cellincorporation in a robust, biocompatible, host thatmaintains cell viability and accessibility while enablingsignal transduction and transmittal. Bulk silica matricesformed by 'classical' sol-gel processing have been usedfor cell entrapment, but alcohol solvents and broad poresize distributions limit cell viability and accessibility.Furthermore, bulk gels are difficult to integrate intodevices like MEMS. Our approach uses evaporationinduced self-assembly (EISA) to immobilize cells withinperiodic silica nanostructures, characterized by unimodalpore sizes and pore connectivity, that can be patternedusing robo-writing or ink-jet printing. Since surfactantstypically used to direct silica self-assembly are bio-incompatible, this project has devised completely newbiocompatible self-assembly approaches to enable bothincorporation of whole cells into MEMS architectures andthe writing of functional bioactive devices in general.Through genetic modification, cell-based sensors can bedeveloped for specific CW, BW or explosive threats.

Keywords: Nanostructure, Self Assembly, MEMS, Ink-Jet Printing, Sensors

318. UNDERSTANDING METAL VAPORIZATIONFROM TRANSIENT HIGH FLUENCE LASERIRRADIATION$85,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Phillip W. Fuerschbach

(505) 845-8877

Laser spot welding is widely used for precision joining ofnuclear weapon components and other high reliabilitydevices. The production of metal vapor as aconsequence of high intensity laser irradiation is aserious concern in cleanrooms, where contamination ofadjacent components, ejection of metal particulates,creation of void defects in the fusion zone, and significantloss of high vapor pressure alloying elements are all

negative consequences of metal vaporization. Despitethe widespread use of laser welding, little fundamentalunderstanding of laser/material interaction in the weldpool exists. Without this fundamental understanding,optimization models cannot be applied to mitigatevaporization problems. Important experiments on 304stainless steel have been completed which haveadvanced our fundamental understanding of themagnitude and the parameter dependence of metalvaporization in laser spot welding. Experimentaltechniques have been developed to easily measure thelaser spotsize on the sample surface, and to quantify thedependence of metal vaporization on laser beamintensity. The experiment was successful in preventinglarge particle ejection and actually quantified the laserbeam intensities required for the onset of spatter as wellas melting. Mass loss measurements were significantwith up to 70 mg loss from each laser pulse. Thevaporized metal has not yet been identified but additionalexperiments and analysis are planned to characterize thevapor, temperature fields on the weld pool surface, anddevelop an analytical model of the vaporizationmechanism.

Keywords: Laser Welding, Laser/Material Interaction,Fusion Zone, Melting, Spatter

319. SCIENCE BASED PROCESSING OF FIELD-STRUCTURED COMPOSITES$100,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Rodney L. Williamson

(505) 845-3105

Field structured composites (FSCs) are anisotropicparticle composites produced in a magnetic or electricfield. They exhibit highly anisotropic properties due to thechain or sheet-like structures that form as a result ofinduced dipolar forces. By producing FSCs in a triaxialmagnetic field and adjusting the relative strengths of thetriaxial field components, a variety of structures can bemade that cannot be produced in any other way. Theseinclude foams, chains, sheets, interpenetrating sheets,and sheets connected by chains. Such structures can bepreserved by producing them in a liquid monomer, whichcan then be polymerized in the presence of the triaxialfield, or by swelling a polymer matrix with a solventcontaining magnetic particles and letting the carriersolvent evaporate in the presence of the field. Field-structuring potentially enables one to produce materialswith tailored material properties to meet specific needs.Recent research at Sandia has shown that thesematerials, when produced with electrically conductiveparticles, exhibit colossal changes in resistance whenslightly strained or when exposed to small changes intemperature, chemical or magnetic environment. Thus,FSCs show great promise as ultrasensitive sensors ifthey can be reliably produced with the desired resistivity.


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These sensors could be made in a wide range of shapesand sizes for many different applications. The goal of thiswork is to learn how to actively control the structure ofthese materials by manipulating the field so thatcomposites with known resistivity can be reliably andreproducibly made. Because several different structuresmay give rise to the same resistance, it is important tocontrol structure so that the proper response to changingenvironmental factors can be achieved. This poses noveland nontrivial feedback control challenges, due to stronghistory effects, diverging timescales, and nonlineardynamics.

Keywords: Field Structuring, Composites,Thermoresistance, Piezoresistance,Magnetoresistance, Chemiresistance

320. DESIGN, SYNTHESIS, ANDCHARACTERIZATION OF SOFT MATTERNANOLAYER SUPERLATTICES$300,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Alfredo M. Morales (925) 294-3540

Recently, birefringent polymer nanolayer superlatticesthat displayed enhanced reflectivities were reported in theliterature. These superlattices consisted of alternatingnanolayers of isotropic polymethyl methacrylate (PMMA)and either birefringent polyester or birefringentsyndiotactic polystyrene. The reflectivities of the p- and s-polarized light from the superlattices were determined bythe indices of refraction of the nanolayers. However, asreported these superlattices are passive materials: oncefabricated, the optical properties cannot be changed inresponse to the reflected light or to a trigger signal. Thisproject seeks to modify by organic chemistry thecomposition of one of the nanolayers to includephotochromic molecules that could change the indices ofrefraction of that set of nanolayers when triggered by anexternal signal. This change in refractive indices willchange the overall reflectivity and the value of theBrewster angle enabling optical switching. We havesynthesizing photoswitchable polymers by appendingazobenzene dies to the PMMA nanolayers. Theazobenzene functionality undergoes a trans-cisphotoisomerization that changes the refractive index ofthe material. To help guide the synthetic effort,computations of optimum geometries and opticalproperties at the semi-empirical level are currentlyunderway for an initial set of diazo compounds. Theresults will be calibrated against available experimentaldata to determine if the semi-empirical methods canreproduce trends in optical properties of substituted diazocompounds. Superlattice fabrication will be carried outwith a modified coextruder. Ultimately, these novelmaterials will be used for fabricating optical microdevices

such as stationary (i.e., no mechanical moving parts)optical switches.

Keywords: Superlattices, Birefringent, Nanolayers,Photochromic, Microdevices

321. PHOTO-CONTROL OF NANO-INTERACTIONS INMICROSYSTEMS$275,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Nelson S. Bell (505) 844-6234

The manipulation of physical interactions betweenstructural moieties on the molecular scale is afundamental hurdle in the realization and operation ofnanostructured materials and high surface areamicrosystem architectures. This work utilizesphotosensitive molecular structures to tune suchinteractions reversibly. This new material strategyprovides optical actuation of nano-interactions impactingbehavior on both the nano- and macroscales andpotential impacting directed nanostructure formation,microfluidic rheology, and tribological control. Activitiesfocus on the identification and examination of organicstructures possessing known photophysical effects thathave a high probability for influencing target interactionprocesses, e.g., physical entanglement,hydrophobicity/philicity, local electrostatic charge or pHchanges. Their incorporation into polymeric chemistrieswill allow their application to inorganic colloids as photo-active surfactants. This will allow the photo-actuatedcontrol of interparticle nano-interactions in self-assembled photonic band gap structures (artificial opals).Primary demonstration of successful nano-interactioncontrol will be provided by photo-induced modulation ofthe photonic band gap in the material.

Keywords: Photosensitive, Photonic, Rheology,Polymeric

322. ELECTROCHEMICALLY DEPOSITED ALLOYSWITH TAILORED NANOSTRUCTURES FORLIGA MICROMACHINES $340,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Dean C. Dibble (925) 294-3417

The performance of LIGA micromachines is directlylinked to the mechanical, magnetic, and tribologicalproperties of the electrodeposited alloys used incomponent fabrication. Surface-active compounds areused in the electrodeposition process to control grainnanostructure, composition, and internal stress of thealloy. Additives dramatically alter these properties, andcan greatly enhance the mechanical strength of thecomponent or they may contribute to undesirable effectssuch as fracture embrittlement. Additives forelectrodeposition processes are empirically developed.


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More importantly, there is little, if any, physico-chemicalunderstanding of the relationship between additivestructure and electrochemical action. We propose todevelop the science base needed for the rationaldevelopment of alloy-deposition processes in LIGA usingadditives and other advanced electrodepositiontechniques (such as pulsed current electrodeposition). Tosuch effect we will develop nanoscale diagnostics thatcan be performed in-situ during electrodeposition. We willuse these diagnostics to characterize in detail theelectrodeposits at the nanometer scale. The efforts ofsuch an investigation will be clearly focused on improvingprocess conditions and they will be facilitated by a closecollaborative effort between fundamental surface scienceand electrochemical engineering methods.

Keywords: LIGA, Electrodeposition, Tribological,Micromachines

323. NEXT-GENERATION OUTPUT-BASEDPROCESS CONTROL: AN INTEGRATION OFMODELING, SENSORS, AND INTELLIGENTDATA ANALYSIS$257,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Richard A. Neiser (505) 845-0457

The goal of process-based quality is to accept WR(weapon reserve) product without inspection. For simpleprocesses, traditional feedback control of process inputvariables might achieve this goal. However, input-based(upstream) control systems are a major source of DPproduction problems for complex processes. With recentadvances in sensor technology, process modeling,intelligent data analysis, and computing power, a broadlyapplicable next-generation control technology thatmonitors and controls process output rather than inputmay now be possible. For real-time, output based(downstream) process control, it is necessary to rapidlyinterpret and correctly respond to large amounts oftemporally and spatially varying data, which requires aninnovative new approach to data analysis. Highlycomplex relationships between process inputs andoutputs must also be correctly modeled, and cost-effective robust sensors must be developed. In addition,relationships between sensor observations and productmicrostructure, properties and performance must beunderstood and integrated into the control system. Forsome complex processes, e.g., thermal spray, a first-generation downstream process controller based on in-flight monitoring and control of the spray plume may beachievable because some of the requisite technologyalready exists. To extract needed information from large,rapidly varying, complex data in real-time, we will createa statistical methodology that combines response surfacemodeling with multivariate statistical process control and

a modified simplex search algorithm that incorporates theconcept of dynamic annealing.

Keywords: Process Control, Sensors, ProcessModeling, Intelligent Data Analysis

324. SOLUTION-BASED NANOENGINEERING OFMATERIALS$320,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: James A. Voigt (505) 845-9044

Solution-based synthesis is a powerful approach forcreating nano-structured materials. We propose todevelop the scientific principles required to design andbuild unique nanostructures in crystalline oxides and II/VIsemiconductors using solution-based molecular self-assembly techniques. The ability to synthesize thesematerials in a range of different nano-architectures (fromcontrolled morphology nanocrystals to surface templated3-D structures) will provide new opportunities for thedevelopment of interactive interfaces for optics,electronics, and sensors. The wide range of interfacialnanostructures of ZnO (hexagonal rods, hollowhexagons, and oriented thin sheets) produced recentlyvia nucleation and growth from aqueous solutionsillustrates the potential of this approach. The key tocontrolled fabrication of such nanostructures lies inunderstanding the factors that control nucleation andgrowth processes. To achieve this understanding, we willconduct systematic nucleation and growth studies thatcombine: 1) synthesis using carefully controlled andmonitored flow reactor systems, 2) characterization ofsurface chemistry and complexation, and 3) molecularmodeling. Unique flow reactors will be used to control allof the critical system parameters such as supersaturationlevels, hydrodynamics, and the concentrations ofadditives that promote nucleation and influence relativegrowth rates on specific crystal faces. Techniques suchas Fourier Transform Infrared (FT-IR) spectroscopy,surface charge measurements, and the interfacial forcemicroscope will be used to monitor the extent andorientation of additive adsorption and what affect suchagents have on interfacial properties. Finally, surfaceenergy calculations based on interatomic potentials willbe used to model ligand adsorption on hydrated crystalsurfaces.

Keywords: Template, Nanostructures, ZnO,Supersaturation


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325. ALL-CERAMIC THIN-FILM BATTERY$310,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Timothy J. Boyle (505) 272-7625

The production of a thin-film, all-ceramic battery forpower sources that generate the necessary power andenergy to operate microsystems without substantiallyincreasing the size of the device are required to achieveautonomy. However, thin-film batteries are currentlyinadequate to operate the microsystems effectively. Weare developing a rechargeable thin-film All-CeramicLithium-Ion Battery (ACB) using solution route depositionmethods. The ACB will have higher power output, longerrun times, and a greatly simplified production scheme incomparison to existing technology. Several ACBprototypes (normal and inverted) have been generatedusing the above chemistries; however, shorting hascomplicated the electronic testing. Once sufficientlydeveloped, these ACB will have the versatility to powerany number of small systems, such as microsystems andminiature autonomous robotics.

Keywords: Batteries, Microsystems, Thin Films,Lithium Ion Battery


326. MATERIALS PERFORMANCE $950,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: William F. Hammetter

(505) 272-7603

This project addresses the need to understandcomposition-structure-performance relationships forcritical non-nuclear materials in current and proposedweapon applications. The work is focused on providingthe scientific basis for materials development andoptimization of properties. Due to the importance offerroelectric materials in stockpile applications, one effortis aimed at understanding the effects of extrinsicvariables such as porosity, PbO stoichiometry, anddopant type and concentration on the properties andferroelectric-antiferroelectric phase transitions ofPb(Zr,Ti)O3 ferroelectrics. In addition, as applicationsapproach the nanoscale, it is critical to understand theeffects of domain size and mobility on ferroelectricresponse. Complimentary work is focused on developinga quantitative model of sintering to predict densification,material compatibility and microstructure developmentduring fabrication of complex ceramic materials, such asmultilayer electronic substrates.

Keywords: Ferroelectric, Ceramic, Sintering,Nanoscale

327. HIGH PRESSURE AND SHOCK PHYSICS$250,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: George A. Samara (505) 844-6653

The goal of this project is to develop continuum andatomic level understanding of shock-induced phenomenain materials used in shock-activated weaponscomponents. Together with complementary high-pressure material physics studies, this work provides newunderstanding of ferroelectrics and polymericencapsulants as well as essential insights to guideperformance and reliability assessments. Looking to thefuture, we expect that micro- and nanoscale materials willfind numerous applications in nuclear weapon systems.Consequently, it will be necessary to measure andunderstand the mechanical properties, especially theshock responses, of the new materials. As a first steptowards this goal, we have recently developed a newcapability at Sandia, the “photonic driver”, whichaddresses both the high per-experiment costs of currentshock methods and the inability of these methods tocharacterize materials having very small dimensions

Keywords: Ferroelectric, Encapsulants, Nanoscale,Photonic, Shock Response

328. AGING OF ORGANIC MATERIALS $485,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Roger L. Clough (505) 844-3492

Work on organic materials aging focuses on providing anunderstanding of degradation mechanisms, developingspecialized analytical techniques for monitoring materialaging at low levels and on short length scales, andproviding methodologies for predicting materialproperties, reliability and lifetimes. One current thrustcomprises identification and modeling of the parametersunderlying radiation-induced conductivity in materials.New approaches employing isotopic labeling using C-13,O-17 and O-18, in combination with the nuclear magneticresonance technique (NMR) or nuclear activationmethods, is yielding information on chemical reactionsunderlying macromolecular degradation mechanisms, atan unprecedented level of detail. Work on interfaces isproviding critical insights into the mechanisms ofadhesion, dewetting and delamination relevant to weaponcomponents. A variety of techniques are being employedfor interfacial studies; one new technique that isparticularly promising in this application is near edge X-ray absorption fine structure (NEXAFS), which is beingdeveloped to allow identification of polymer surfacestructure.

Keywords: Degradation, NMR, Radiation, NEXAFS,Reliability


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329. CORROSION SCIENCE AND METALDEGRADATION $135,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Jeffrey W. Braithwaite

(505) 844-7749 and Charles H. Cadden (925) 294-3650

The physical and electrical properties of metals cansignificantly degrade over time because of interactionswith the environment. The objective of this project is todevelop the mechanistic understanding and, as required,associated characterization techniques of selectedcorrosion-related degradation phenomena of bothimmediate and longer-term relevance to stockpile issues.Importantly, the advancements made in this taskconstitute the needed physical basis for 1) emerginganalytical toolsets that will be used to predict the effectsof metal aging on component service life, and 2) definingstrategies that will enable real-time state-of-health sensortechnologies to be developed. The processes currentlybeing studied include: (a) corrosion of small-featurealuminum metallization features under atmosphericconditions (microelectronic devices) (b) theenvironmental degradation of coated and/or passivatedpolycrystalline silicon (surface micro-machined devices),and (c) the aging of LIGA-based microsystem materials.

Keywords: Corrosion, Passivated, Microsystem, Aging,Degradation

330. SURFACE AND INTERFACE RELIABILITY$529,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Kevin F. McCarty (925) 294-2067

The engineered microstructures of metals enable theperformance of many non-nuclear components in nuclearweapons. Time-dependent changes of microstructure canlead to failure of stockpile components. A new and largeissue that needs to be addressed is the aging (dormancy)of microsystem parts produced by the LIGA process,which uses electrodeposition for part fabrication.Because of the central role of microstructure in stockpilecomponents and anticipated replacement componentsbased on microsystems, this research task is focused onsome of the fundamental aspects of metal microstructure.We emphasize the relationship between microstructureand mechanical properties such as yield strength. Todevelop predictive capability for performance and lifetime,we perform both simulation and experiment. This taskhas three major thrusts: 1) grain-boundary structure anddynamics, 2) microstructure of electrodeposited metals,and 3) computational-technique development.

Keywords: Time-Dependent, Microstructure,Electrodeposition, Lifetime, Grain-Boundary

331. NANOMECHANICS$250,000DOE Contact: Larry Newkirk (202) 586-7831SNL Contact: J. Charles Barbour (505) 844-5517

The goal of this effort is to develop a preciseunderstanding of the high strain-rate behavior ofmaterials at small length scales. For materials modeling,code development and implementation is done tounderstand the mechanical properties of materials. Thismodeling will ultimately link electronic and atomic-levelproperties to the continuum level. For materialsexperimentation, new methodologies of producingatomically-tailored materials and testing the mechanicalresponse of these materials are required. In addition, newtest structures are being developed with submicron-scalecomponent features.

Keywords: Mechanical, Modeling, Atomic-Level,Mechanical, High Strain Rate

332. MICRO-MECHANICAL BEHAVIOR ANDTRIBOLOGY$200,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Jonathan S. Custer (505) 845-8594

The goal of this project is to improve the fundamentalunderstanding of the microstructural mechanisms andtopographical features that control mechanical andtribological behavior of materials. Tools and techniqueswill be developed to measure materials performance atlength scales that are consistent with microstructuraldimensions.

Keywords: Mechanical, Topographical, Tribological,Microstructural, Microsystem

333. MAGNETIC-FIELD EFFECTS ON VACUUM-ARCPLASMAS$225,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Paul A. Miller (505) 844-8879

The main goals of this project are to understand the roleof the self-magnetic field on the vacuum-arc ion source inneutron tubes and to realize magnetic shaping of theplasma plume from the ion source, thereby enablingincreased plasma utilization efficiency, reduced stress onthe electrode films, and reduced electrical driverequirements. We have shown experimentally thatuniform applied fields (< 300 Gauss) strongly influencethe arc impedance, the shape of the plasma plume, andthe total ion output. We have studied magnetic effectscomputationally with the Large Scale Plasma (LSP) code.Two-dimensional magnetostatic calculations agree withsome of the measurements and three-dimensionalelectromagnetic calculations are under development.


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Compact neutron tubes employ annular ion beams inorder to minimize adverse defocusing effects due to thespace charge of the ions in the beam. If we can usemagnetic fields to form plasma into an annular shape,then we can use all the plasma. More efficient use of theplasma would reduce the performance requirements onthe thin-film electrodes of the vacuum arc, which providethe plasma ions, and reduce the electrical driverequirements for the ion source.

Keywords: Vacuum-Arc Plasmas, Magnetic Fields,Plasma Plume, Langmuir Probe

334. FIRST-PRINCIPLES DETERMINATION OFDISLOCATION PROPERTIES$170,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: John C. Hamilton (925) 294-2457

Dislocation behavior determines numerous materialsproperties. Their motion produces deformation. Theinteraction of dislocations with interfaces produces thegrain-size dependence of strength. Motion of dislocationsin boundaries determines the boundary mobility andthereby microstructural evolution. Prediction ofdislocation core structures at the atomistic level inarbitrary materials and ultimately in the presence ofdefects is central to developing predictive models ofmaterial evolution. The need to treat arbitrary materials,alloys and dopants requires a predictive first-principlesapproach. Current first-principles modeling capabilitiesare not well suited to the description of dislocationproperties. Techniques for determining the electronicstructure of large numbers of atoms (order-N methods)work well for insulating materials but not for metallicsystems. Further, essentially all ab-initio modeling to dateemploys band structure techniques with periodicboundary conditions. Thus dislocations and otheraperiodic defects are difficult to model. We will adapt acombined electronic/lattice Green's technique to thedirect calculation of dislocation core structures, whichavoids the requirement of periodic boundary conditions.Both Green's functions exploit the short-range characterof the Hamiltonians defining them. Additional modelingusing an ab-initio extension of Peierls-Nabarro is alsobeing pursued. The result of these calculations can bevalidated by detailed comparison with high-resolutionelectron microscopy observations. The success of thisproject will create a new world-class tool for thefundamental study of dislocation properties.

Keywords: Dislocations, First-Principles Modeling,Hamiltonians

335. DYNAMICS OF METAL/CERAMIC INTERFACES$160,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Kevin F. McCarty (925) 294-2067

The goal of this project is to understand howmetal/ceramic interfaces form, evolve, and accommodatethe stress that can lead to delamination and failure. Weemphasize the use of advanced microscopies such asscanning-tunneling microcopy and low-energy-electronmicroscopy to observe interface formation in real time.These techniques are used to measure the interfacialwork of adhesion, determine the mechanisms andkinetics of interface formation, and developunderstanding of how stress is or is not accommodated.

Keywords: Metal/Ceramic Interfaces, Microscopy,Adhesion

336. IN-SITU CHARACTERIZATION OF SOFTSOLUTION PROCESSES FOR NANOSCALEGROWTH$100,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Nelson S. Bell (505) 844-6234

The study of novel materials and structures withdimensions in the nanoscale (< 100 nm) regime is animportant, emerging field of materials science. The smallsize of these materials results in quantum confinementand surface contributions that translate into novel opto-electronic properties whose applications are still beingrealized. Many synthesis techniques for nanomaterialsare based on soft solution processes (SSP), whichinclude sol-gel, hydrothermal, solvothermal, micellular ororganic templating routes, and electrochemical methods.These processes involve the precipitation of ionic speciesor metal-organic molecules into nanoparticles ornanostructured networks. In order to exercise a highdegree of control over these processes, it is critical tohave a capability for following the development ofsupersaturation, surface processes, and formation of aprecipitating system in-situ. This proposal will study thesuperposition of different measurement techniques tocharacterize dynamic colloidal systems in novel ways.These studies will probe the chemical interactions duringreactions, and the organizational characteristicsdeveloped in the resulting colloids.

Keywords: Nanomaterials, Soft Solution Processes,Colloids


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337. DETERMINATION OF CRITICAL LENGTHSCALES FOR CORROSION PROCESSES USINGMICROELECTROANALYTICAL TECHNIQUES$160,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Kevin R. Zavadil (505) 845-8442

A key factor in our ability to produce and predict thestability of metal-based macro- to nano-scale structuresand devices is a fundamental understanding of thelocalized nature of corrosion. Corrosion processes wherephysical dimensions become critical in the degradationprocess include localized corrosion initiation in passivatedmetals, micro-galvanic interactions in metal alloys, andchemistry in adsorbed water films in atmosphericcorrosion. This work focuses on two areas of corrosionscience, where a fundamental understanding ofprocesses occurring at critical dimensions is not currentlyavailable. We will study the critical length scalesnecessary for passive film breakdown in the inundated Alsystem and the chemical reactions and transport in ultra-thin water films relevant to the atmospheric corrosion ofAl. We will combine low current measurements withmicroelectrodes to study the size scale required toobserve a single initiation event and recordelectrochemical breakdown events. The resultingquantitative measure of stability will be correlated withmetal grain size, secondary phase size and distribution tounderstand which metal properties control stability at themacro- and nano-scale. Mechanisms of atmosphericcorrosion on Al are dependent on the physicaldimensions and continuity of adsorbed water layers aswell as the chemical reactions that take place in thislayer. We will combine microelectrode arrays withelectrochemical sensing and electrostatic forcemicroscopy to monitor the chemistry and ion transport inthese thin layers. The techniques developed andinformation derived from this work will be used tounderstand and predict degradation processes inelectrical and structural components.

Keywords: Corrosion Science, Microelectrodes,Degradation Processes

338. EXPLORATION OF NEW MULTIVARIATESPECTRAL CALIBRATION ALGORITHMS$152,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: David M. Haaland (505) 844-5292

We have developed a number of powerful newmultivariate calibration algorithms that have beendemonstrated to correct many of the outstandinglimitations of traditional quantitative multivariate spectralcalibrations and to greatly extend our ability to solve newproblems. We have developed a family of augmentedclassical least squares (ACLS) multivariate algorithms,and we have greatly improved multivariate curve

resolution (MCR) methods. The ACLS algorithms havethe ability to be rapidly updated during prediction withoutrecalibration while the MCR techniques allow us toperform multivariate calibrations without the use ofstandards. The rapid updating feature of the ACLSalgorithms is a significant advantage over previouschemometric algorithms. For example, the new ACLSalgorithms can take advantage of weighted least squaresmethods to accommodate non-uniform noise in spectraldata. The ability to better handle non-uniform spectralnoise will be tested with simulation calibration data. Theimproved MCR capabilities will be used to test ourhypothesis that they can be used to improve spectralcalibrations that are currently limited by the referencemethods required to build multivariate calibrationmethods. Since reference errors are often the limitingfactor in multivariate spectral calibrations, reducing oreliminating this limitation would be a significant advancein chemometric data analysis capabilities. If we cansuccessfully reduce the impact of reference errors inspectral calibrations, then we also have the opportunity todetermine if the generally high precision of spectralmeasurements can be used to decrease errors in theprimary reference methods. Success at this goal couldhave a very significant impact on all our instrumentalanalytical reference tools.

Keywords: Multivariate Calibration, HyperspectralImage

339. NANOSTRUCTURED MATERIALS FORDIRECTED TRANSPORT OF EXCITATIONENERGY$300,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Michael B. Sinclair (505) 844-5506

One functionality that is extremely desirable fornanostructured materials is the ability to efficientlyactivate or interrogate structures within a nanomaterialusing optical energy. However, given the packingdensities obtainable with nanofabrication, direct focusingof incident optical energy onto individual nanostructuresis impractical. The project will determine how thephenomenon of energy transfer can be harnessed toprovide this functionality. Energy transfer is the processby which excitation energy resulting from absorption ofphotons can become delocalized and move from the sitewhere the photon was absorbed. Energy transfer plays aprominent role in the photosynthetic process, where "lightharvesting antennas" efficiently absorb sunlight anddeliver the excitation energy to the photosyntheticreaction center. The antennas comprise arrays ofabsorbing organic chromophores that are coupled vianear-field electromagnetic interactions. We will use thetools of nanotechnology to control the structure, and,hence, the energy transport properties of chromophorearrays. We will use nanolithography to pattern substrates


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in a manner that will allow us to measure the extent ofdelocalization in chromophore arrays. We will also usenanolithography to create site-energy and site-spacinggradients within chromophore arrays in an effort to driveexcitation energy transport in predetermined directions.We will also utilize self-assembly techniques such as self-assembled monolayers and Langmuir-Blodgett films tocontrol the growth, structure and energy transportproperties of chromophore arrays. Recent theoreticalinvestigations have lead to the prediction that surfaceplasmon coupling between adjacent nanoparticles inmetallic nanoparticle chains can lead to energydelocalization and transport. We will fabricate metallicnanoparticle chains using both nanolithography and self-assembly. Using a variety of optical microscopies, we willdevelop methods to couple electromagnetic energy intothese structures, and characterize their energy transportproperties.

Keywords: Nanomaterial, Chromophore,Delocalization, Nanolithography

340. THE EFFECTS OF VARYING HUMIDITY ONCOPPER SULFIDE FILM FORMATION$200,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: John P. Sullivan (505) 845-9496

Atmospheric corrosion of electrical components has beenlinked to a significant number of materials-related issuesfor the nuclear weapons stockpile. Further, the increasinguse of Cu in commercial systems will require a long-termcommitment to understand Cu corrosion mechanisms inorder to reliably predict corrosion rates for commercialoff-the-shelf (COTS) discrete components in the futurestockpile. This project will study the effects of varyingrelative humidity (RH) in the sulfidation of copper - ademonstrated and recurring corrosion problem forelectrical devices. The complex interactions between asulfidizing environment and an oxidized Cu surface aredependent upon RH and temperature. Small changes inthe ambient temperature near room temperature maycause significant changes in the sulfidation mechanismthat can lead to greatly differing morphology of thecorrosion product layer. This corrosion product layer,primarily Cu2S, can impede mechanical functions ofconnectors and switches and alter the performance ofelectrical components. A detailed study of the criticalsteps during the initial stages of water layer adsorption onan oxidized copper surface and subsequent Cusulfidation will allow identification of the relevantmechanisms governing the sulfide nucleation and growthprocesses. Our measurements will identify critical kineticprocesses in the initial stages of growth, in order toultimately obtain quantitative, predictive models of Cusulfidation. This project is the most effective method tofocus research efforts onto a study of the effects ofvarying humidity on copper sulfide film formation, and to

provide the freedom to pursue the high-risk/high-payoffexperiments proposed herein.

Keywords: COTS, Sulfidation, Corrosion, Humidity

341. MECHANISMS OF DISLOCATION-GRAINBOUNDARY INTERACTION$264,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Robert Q. Hwang (925) 294-1570

Incorporating the localized atomistic and microscopiceffects of internal interfaces on materials properties andlong-term behavior is a significant challenge for large-scale materials simulations. Critical to improving suchmodels is developing an improved understanding of thedislocation-grain boundary interactions that ultimatelycontrol the interfacial response to strain. Suchinteractions impact many materials phenomena andproperties including slip transmission, boundarymigration, recrystallization, and yield strength and are acritical element in linking atomic structure to continuumbehavior. In this project we seek to develop anexperimentally based understanding of these dislocation-grain boundary interactions.

Keywords: Dislocation, Grain Boundary

342. PHYSICAL BASIS FOR INTERFACIALTRACTION - SEPARATION MODELS$297,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: E.David Reedy (505) 844-3297

Many components contain interfaces between dissimilarmaterials where cracks can initiate and fail components.In recent years, researchers in the fracture communityhave adopted a cohesive zone model for simulating crackpropagation (based upon traction-separation relations).Sandia is implementing this model in its ASCI codes.However, one important obstacle to using a cohesivezone modeling approach is that traction-separationrelations are chosen in an ad hoc manner. The goal ofthe present work is to determine a physical basis formesoscale level Traction-Separation (T-U) relations. Wepropose experiments that will elucidate the dependenceof such relations on adhesive and bulk properties. Workwill focus on epoxy/solid interfaces, although theapproach is applicable to a broad range of materials. Thecrucial roles of crack tip plastic zone size and interfacialadhesion are being defined by varying epoxy layerthickness and using coupling agents or special self-assembled monolayers (SAMs) in preparing samples.The nature of the yield zone will be probed incollaborative experiments run at the Advanced PhotonSource, and high-resolution optical methods will be usedto measure crack opening displacements of the SDCBspecimens. This work will provide an understanding of


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the major mesoscale phenomena governingpolymer/solid interfacial fracture and identify the essentialfeatures that must be incorporated in a T-U basedcohesive zone failure model. We believe that modelsusing physically based T-U relations will provide anessential tool for using models to tailor interfaceproperties to meet design needs.

Keywords: Traction-Separation, Interfacial Fracture

343. MAKING THE CONNECTION BETWEENMICROSTRUCTURE AND MECHANICS$257,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Elizabeth A. Holm (505) 844-7669

The purpose of microstructural control is to optimizematerials properties. To that end, we have developedsophisticated and successful computational models ofboth microstructural evolution and mechanical response.However there is currently no way to couple thesemodels to quantitatively predict the properties of a givenmicrostructure. The problem arises because continuousresponse models, such as finite element, finite volume, ormaterials point methods, do not incorporate a real lengthscale. In this project, we are taking a tiered risk approachto incorporate microstructure and its resultant lengthscales in mechanical response simulations. Thesuccessful coupled model will predict both properties as afunction of microstructure and microstructuraldevelopment as a function of processing conditions.

Keywords: Microstructure, Mechanical Properties,Computational Materials Science

344. DIAGNOSTICS FOR JOININGSOLIDIFICATION/MICROSTRUCTURALSIMULATIONS$327,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Charles V. Robino (505) 844-6557

Solidification is an important aspect of welding, brazing,soldering, LENS fabrication, and casting. For theseprocesses solidification affects, and in many instancescontrols, the final microstructure and properties of theproduct. The current trend toward utilizing large-scaleprocess simulations and materials response models forsimulation-based engineering is driving the developmentof new modeling techniques. However, the effectiveutilization of these models and simulations is currentlylimited by a lack of fundamental understanding of thesub-processes and interactions involved. This project isidentifying key physical phenomena in, and expandingand refining our mechanistic descriptions of, solidificationin the Fe-Cr-Ni system. The experimental study iscoupled to modeling efforts focused on solidificationprocesses in the same alloy system, and provides

necessary mechanistic descriptions and input data forthese models. We have developed and will continue torefine new and expanded experimental techniques,particularly those needed for in-situ measurement of thekinetics features of the solidification process. Thisapproach has identified several unexpected features ofthe solidification process, including the observation thatthe solidification front is more dynamic than previouslythought and the observation of a previously unreportedorientation relationship between ferrite and austenite.

Keywords: Solidification, Ferrite, Austenite, Joining

345. EFFECTS OF MICROSTRUCTURAL VARIABLESON THE SHOCK WAVE RESPONSE OF PZT 95/5$321,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: George A. Samara (505) 844-6653

Sandia has responsibility for the design and production ofneutron generators. Most generators use explosivelydriven power supplies in which shock wave depoling ofthe ferroelectric ceramic PZT 95/5 provides the requiredhigh voltage for the neutron tube. Generator productionwill change within a few years to PZT 95/5 materialprepared using a new "chem prep" process that is stillunder development. This process will introduce a porousmicrostructure that is significantly different than thatfound within most material presently in the stockpile.Early studies showed that the porous microstructure canhave a profound effect on performance: the rate forfailures due to high-voltage breakdown at lowtemperatures is acceptably low only in materials madewithin a narrow density range through the addition oforganic pore formers. More fundamentally, the dielectricand ferroelectric properties of the material and thephysics of the FE (ferroelectric)-to-AFE (antiferroelectric)phase transformation that governs the depoling processdepend on microstructural properties in ways that are notwell understood. This project represents the firstsystematic study of the basic physics of microstructuraleffects on PZT 95/5 electromechanical behavior undershock loading. Dielectric properties are characterized formaterial samples having different densities, and theelectromechanical responses of similar samples areinvestigated under carefully controlled shock loadingconditions. Results to date demonstrate significantporosity effects on both the dynamic material responseand shock-induced depoling, provide insight into arecently confirmed failure mechanism, and underscorethe continuing need for systematically examiningmicrostructural variables.

Keywords: Shock Wave Depoling, Ferroelectric,PZT 95/5, Phase Transition


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346. THE BASICS OF AQUEOUS NANOFLUIDICS:"INTERPHASE" STRUCTURE AND SURFACEFORCES$300,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Peter J. Feibelman (505) 844-6706

To understand flow through narrow pores, biomaterialsproperties, micro-machine operation and other keynanofluidic phenomena, we need to learn how theunexpectedly strong forces measured as far as tens ofnanometers from water-solid interfaces are mediated bynear-surface water structure. Using ab-initio calculationsand a suite of incisive experiments, we will identify andcharacterize ice-like, clathrate-like and possibly otherarrangements of water molecules in the "interphase"adjacent to ice-nucleating, hydrophobic and intermediatesurfaces. The measurement techniques, includinginfrared spectroscopy, interfacial force microscopy,contact angle studies, will illuminate the relations amonginterphase structure and energetics, mechanicalproperties and hydration forces. Our theoretical effortswill target an explanation of how templates produced bystrong short-range interactions nucleate near-surfaceordering of water molecules. For this purpose, we willdevelop and deploy a computational scheme in which thenear-surface transition region is described by a classicalwater potential, specifically designed to reproduce the ab-initio phases and properties of bulk water, while an ab-initio description of the immediate surface vicinityprovides a boundary constraint amounting to a template.After initial work in which novel experimental andtheoretical methods are developed and validated, we willapply theory and experiment concurrently to a set ofrepresentative cases, including an AgI surface (epitaxywith ice), a clean metal and a self-assembled-monolayer-covered (oily) surface. We will thus learn the microscopicunderpinnings of the relation between hydration forcestrength, surface chemistry (e.g., hydrophilicity) andphysics (e.g., epitaxial match).

Keywords: Water, Ice-Like, Clathrate-Like, Ab-Initio,Monolayer

347. MODELING LOCAL CHEMISTRY IN THEPRESENCE OF COLLECTIVE PHENOMENA$170,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Normand A. Modine (505) 844-8412

Many materials science problems are characterized bythe interplay of two phenomena: chemical specificity(CS), controlled by the detailed behavior of chemicalbonds, and collective phenomena (CP), where newbehavior emerges from many body interactions. We aredeveloping the world's first robust and efficient model

bridging the length scales involved in these phenomena.In order to maintain a preeminent focus on materialsscience, we apply our approach to obtain anunprecedented understanding of the interplay betweenchemistry and collective phenomena during the aging ofa complex material system, Zeolite-3A-based desiccants.Such investigations require a coupling of quantummechanical (QM) methods and classical methods into thesame simulation since classical simulation techniquesalone cannot model CS reliably, while QM methods aloneare incapable of treating the extended length and timescales characteristic of CP. In typical situations, wherethe reactions responsible for CS are localized, while theweaker, longer range interactions involved in CP can beclassically represented, an efficient QM-to-classicalcoupling can be obtained by exploiting the natural spatiallocality of electronic structure (Kohn's nearsightedness).In addition to the aging and reliability of desiccants, ourmodel eventually could be applied to problems such as 1)Science-based processing for ceramic/metal joints, e.g.,in neutron tubes, where the relationship betweenchemical composition (CS) and interface integrity (CP) ispoorly understood; and 2) Proteomics, where active sites(CS) interact with a complex background consisting of therest of the protein and its aqueous environment (CP).

Keywords: Collective Phenomena, ChemicalSpecificity, Quantum Mechanical


348. ASSURING ULTRA-CLEAN ENVIRONMENTS INMICRO-SYSTEM PACKAGES: IRREVERSIBLEAND REVERSIBLE GETTERS$365,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Leroy L. Whinnery (925) 294-3410

Microsystems are currently being evaluated as possiblereplacements for a number of weapon subsystems withthe expectation of improved surety combined withreduced weight and volume. However, there is greatconcern that long periods of dormant storage may impairthe mechanical functioning of microdevices that areexposed to water, out gassing products and particulates.Low-temperature operating environments and smallmoving parts in contact with stationary and matingstructures make capillary condensation, ice formation andcorrosion true concerns for microsystems. We aredeveloping a new generation of irreversible, chemicallyreacting getters specifically targeted toward assuring theintegrity of the local environment within microsystempackages. We intend to incorporate reactive volatilespecies into a polymer through covalent bonds, thusproducing a non-volatile product. These reactive getterswill be combined with getters that rely on absorptionmedia (e.g. zeolites and high surface area carbon fibers)


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to scavenge non-reactive species, like solvents. Ourgetter systems will rely on device packaging to limitexchange between the microsystem and the globalweapon environment. Thus, the internal getters need onlyprovide local environmental control within themicrosystem package. Modeling and analysis of availabledata will be used to estimate the ingress of undesirablespecies as well as the gettering rates, capacities, andgeometries needed to maintain an acceptableenvironment within the package.

Keywords: Getter, Microdevices, Packaging,Absorption

349. MECHANICS AND TRIBOLOGY OF MEMSMATERIALS$270,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Michael T. Dugger (505) 844-1091

Micromachines have the potential to significantly impactfuture weapon component designs as well as otherdefense, industrial, and consumer product applications.For both electroplated (LIGA) and surface micromachined(SMM) structural elements, the influence of processingon structure, and the resultant effects on materialproperties are not well understood. The behavior ofdynamic interfaces in present as-fabricated microsystemmaterials is inadequate for most applications and thefundamental relationships between processing conditionsand tribological behavior in these systems are not clearlydefined. We intend to develop a basic understanding ofdeformation, fracture, and surface interactionsresponsible for friction and wear ofmicroelectromechanical system (MEMS) materials. Thiswill enable needed design flexibility for these devices, aswell as strengthen our understanding of material behaviorat the nanoscale. The goal of this project is to developnew capabilities for sub-microscale mechanical andtribological measurements, and to exercise thesecapabilities to discover fundamental knowledge ofmaterial behavior at this size scale. Novel micro-forceand displacement sensors using SMM technology andnew methodologies for isolating local variations inmechanical response of MEMS materials will bedeveloped. Increased understanding of MEMSmechanics and tribology developed in this project willpermit performance and reliability of advanced MEMScomponents to be predicted with a sound scientific basis.

Keywords: Micromachines, Interfaces, Tribology,Surface Interactions

350. LIGA MICROSYSTEMS AGING: EVALUATIONAND MITIGATION$360,000DOE Contact: Gerald Green (202) 586-8377SNL Contact: Charles H. Cadden (925) 294-3650

The deployment of LIGA structures in DP applicationsrequires a thorough understanding of potential long-termphysical and chemical changes that may occur duringservice. While these components are generally fabricatedfrom simple metallic systems such as copper, nickel andnickel alloys, the electroplating process used to formthem creates microstructural features which differ fromthose found in conventional (e.g. ingot metallurgy)processing of such materials. Physical changes in non-equilibrium microstructures may occur due to long-termexposure to temperatures sufficient to permit atomic andvacancy mobility. Chemical changes, particularly at thesurfaces of LIGA parts, may occur in the presence ofgaseous chemical species and contact with other metallicstructures. We propose to characterize LIGA materials,including pure Ni, Ni-Co and Ni-Fe alloys. This baselinecharacterization will be used as a reference point as wemonitor changes that occur in LIGA structures overextended time periods in environments similar to thoseenvisioned for DP applications. Finally, conformal coatingsystems will be investigated as needed to combatenvironmental degradation occurring at LIGA surfaces.

Keywords: LIGA, Electroplating, Non-EquilibriumMicrostructures


351. ADVANCED ANALYTICAL TECHNOLOGYPROJECT$735,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Raymond P. Goehner

(505) 844-9200

Our goal is to develop analytical sensors and techniquesto detect the early indications of aging in materials thatwill enable the detection and quantification of thechemical and physical mechanisms that cause materialsproperties to change with time. Areas of emphasisinclude: 1) microstructural techniques using electron,X-ray, neutron and ion beams to perform structural,chemical, and phase analysis on the nanometer tomicron scale of complex materials; 2) application anddevelopment of spectrum imaging techniques applied toelectron microscopes equipped with X-ray and electronenergy loss spectrometers and three-dimensionalspectrum imaging of near-surface regions and largervolumes; 3) improve optical and mass spectrometry


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techniques to probe subtle chemical changes that takeplace as materials in weapon systems age.

Keywords: Sensors, Aging, Structural Characterization,Chemical Analysis, Electron Microscopy

352. INFORMATION EXTRACTION$500,000DOE Contact: Syed Zaidi (301) 903-3446SNL Contact: Nancy B. Jackson (505) 845-7191

Creating and applying new algorithms for the analysis ofspectroscopic and materials characterization data is thefocus of this project. These algorithms are the basis ofimproved multivariate analysis methods that haveapplications in polymer aging, microsystems, processmonitoring, chemical analysis techniques, quality control,sensors, and remote sensing. Software will be developedthat will allow expert and non-expert alike to be able toincorporate Sandia state-of-the-art Multivariate CurveResolution (MCR) algorithms in the analysis of images.Applications using these algorithms will be used toimprove developed analytical instruments including Time-of-Flight Secondary Ion Mass Spectrometry (TOF-SIMS),X-ray photoelectron spectroscopy (XPS), and AugerElectron Spectroscopy (AES), and for developing newanalysis tools such as AFM/FTIR, a combination ofatomic force microscopy (AFM) technology with a Fouriertransform infrared (FTIR) source for high resolutionanalysis. Also, techniques using photoacoustic infraredspectroscopy (PAS) and Raman imaging will bedeveloped for analysis of polymeric materials, and siliconmicrosystems, respectively.

Keywords: Algorithms, Multivariate Analysis,Spectroscopy, AFM/FTIR

LOS ALAMOS NATIONAL LABORATORY

353. ENHANCED SURVEILLANCE CAMPAIGN$15,223,000DOE Contacts: E. Cochran (301) 903-7330 and

S. Zaidi (301) 903-3446LANL Contacts: K. B. Alexander (505) 665-4750

and R. Krabill (505) 667-4286

The Stockpile Surveillance Program provides protectionto the U.S. nuclear weapons stockpile by an intensiveprogram that assures it is free of defects that may affectperformance, safety, or reliability. It consists of twoelements, the Stockpile Evaluation Program and theEnhanced Surveillance Campaign. The StockpileEvaluation Program provides the examinations andassessments of WR stockpile weapons and components.The Enhanced Surveillance Program provides means tostrengthen the Stockpile Evaluation Program to meet thechallenges of an aging stockpile in an era of no nuclear

testing as well as providing lifetime assessments andpredictions for lifetime extension program (LEP) planning.

The Enhanced Surveillance Campaign will protect thehealth of the stockpile by providing advance warning ofmanufacturing and aging defects to allow refurbishmentbefore performance is impaired. The Campaign willprovide diagnostics for screening of weapons systems toidentify units that must be refurbished as well as for earlydetection of defects. It will also predict material andcomponent aging rates as a basis for annual certification,refurbishment scope and timing, and nuclear weaponcomplex planning. Results of the work will includeimprovements to the basic Surveillance Program. Sincenuclear weapons will be retained in the stockpile forlifetimes beyond our experience, the Department ofEnergy (DOE) needs a firm basis on which to determinewhen stockpile systems must be refurbished orreconditioned. If new refurbishment capability is needed,the DOE needs to know:

• When these capabilities must be operational andwhat the required capacity should be

• If the capacity for existing facilities is adequate andwhen potential refurbishment for the variousstockpile systems must be scheduled

• A basis from which to characterize the functionalreliability of aged components, as part of the annualassessment process

The work in the ES Campaign began in late FY97. Theprincipal milestones and deliverables for this campaignare below:

• Provide a stockpile aging assessment annually foruse in performing the annual assessment of thestockpile annually)

• Provide component lifetime assessments forweapon refurbishments to enable componentreplacement decisions and age-aware componentdesign and material selections

• Provide data or requirements to enable facilityplanning, design, and construction

• Develop validated models for the aging of materials,components, and systems for use in weaponcertification

• Deliver advanced diagnostic tools to enable morepredictive, higher fidelity, and non-destructivesurveillance test capability

Our work is divided into five major technical elements(MTE): pits, CSAs/Cases, high explosives (HE), systems,and non-nuclear materials (NNM). The pit, CSA/Cases,and high explosives MTEs are each divided into twoprojects; lifetime assessments and diagnostics. TheSystems MTE is responsible for assessments/methodologies to support decision making underuncertainty. The Non-nuclear materials MTE is divided


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into two projects; material lifetimes and advanceddiagnostic tools.

Complete details for the Enhanced SurveillanceCampaign can be found in the ESC Program Plan andthe ESC Implementation Plan, which are updated on ayearly basis.

Keywords: Nuclear Weapons, Pits, Plutonium, CSA,Canned Subassembly, High Explosives,Non-Nuclear Materials, Systems, Reliability,Energetic Materials, Stockpile, EnhancedSurveillance, Campaign 8, AcceleratedAging, Lifetime prediction, Aging

LAWRENCE LIVERMORE NATIONAL LABORATORY


354. ENGINEERED NANOSTRUCTURE LAMINATES$2,750,000DOE Contact: Bharat Agrawal (301) 903-2057LLNL Contact: Troy W. Barbee, Jr. (925) 423-7796

Multilayers are man-made materials in which compositionand structure are varied in a controlled manner in one ortwo dimensions during synthesis. Individual layers areformed using atom by atom processes (physical vapordeposition) and may have thicknesses of from onemonolayer (0.2nm) to hundreds of monolayers (>100nm).At this time more than 75 of the 92 naturally occurringelements have been incorporated in multilayers inelemental form or as components of alloys orcompounds. In this work deposits containing up to225,000 layers of each of two materials to form up to 500mm thick samples have been synthesized for mechanicalproperty studies of multilayer structuresand energetic materials development.

These unique man-made materials have demonstratedextremely high mechanical performance as a result of theinherent ability to control both composition and structureat the near atomic level. Also, mechanically active flawsthat often limit mechanical performance are controllableso that the full potential of the structural control availablewith multilayer materials is accessible. Systematic studiesof a few multilayer structures have resulted in free-standing foils with strengths approaching those ofwhiskers, approximately > 50 percent of theory. Also,new mechanisms for mechanically strengtheningmaterials are accessible with nanostructure laminates.

Applications now under development include: IR, Vis, UV,EUV, soft X-ray and X-ray optics for spectroscopy andimaging; energetic materials, high performancecapacitors for energy storage; capacitor structures for

industrial applications; high strength materials; integratedcircuit interconnects; projection X-ray lithography optics.

Keywords: Precision Thin Films, MultilayerTechnology, Passive Elecrtonic Devices,Energetic Materials, IR, Visible, UV, EUV,SXR and XR Optics, Optic Systems


355. AFM INVESTIGATIONS OFBIOMINERALIZATION$113,000DOE Contact: Nick Woodward (301) 903-4061LLNL Contact: J. J. DeYoreo (925) 423-4240

Living organisms use organic modifiers of nucleation andgrowth to control the location, size and shape ofmineralized structures. While much is known about themacroscopic impact of these growth modifiers or hasbeen inferred about the microscopic interfacialrelationships between the modifiers and crystal surfaces,the atomic-scale mechanisms of biomineralization arepoorly understood. In this project we use atomic forcemicroscopy, molecular modeling and surfacespectroscopy to investigate the effects of small inorganicand organic growth modifiers as well as proteins and theirsub-segments on the growth of single crystal surfacesfrom solution. From these measurements we seek todetermine growth mechanisms, geometrical relationships,and the effect on the thermodynamic and kineticparameters controlling growth morphology and rate.

Keywords: Biomineralization, Atomic ForceMicroscopy, Crystal Growth

356. POLYIMIDE COATING TECHNOLOGY FOR ICFTARGETS$1,400,000DOE Contact: Bharat Agrawal (301) 903-2057LLNL Contacts: R. Cook (925) 422-3117 and

Steve Letts (925) 422-0937

This program has as its objective the development of avapor deposition based polyimide coating technology toproduce a smooth 150 :m polyimide ablator coating on a2mm diameter capsule target for the National IgnitionFacility (NIF). The approach involves first vapordepositing monomeric species to form a polyamic acidcoating on a spherical hollow mandrel. The surfaces ofthese coated mandrels are then smoothed by exposureto dimethyl sulfoxide vapor while being levitated on anitrogen gas flow. The smoothed shells are then heated


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in situ to imidize the coatings. The focus of the past yearhas been improvement of the capsule surface finish.

Keywords: Polymers, Laser Fusion Targets, Polyimide,Ablator

357. BERYLLIUM ABLATOR COATINGS FOR NIFTARGETS$400,000DOE Contact: Bharat Agrawal (301) 903-2057LLNL Contacts: R. McEachern (925) 423-4734,

R. Cook (925) 422-3117 and R. Wallace(925) 423-7864

This program has as its objective the development ofmaterials and processes that will allow sputter-depositionof up to 200 :m of a uniform, smooth, high-Z dopedBe-based ablator on a spherical hollow mandrel.Capsules made with this type of ablator have beenshown by calculation to offer some important advantagesas ignition targets for the National Ignition Facility (NIF).Emphasis in the past year has been on improving coatinghomogeneity and smoothness by reducing grain size anddeveloping laser drilling techniques that will be neededfor capsule filling.

Keywords: Beryllium, Laser Fusion Targets, Ablator,Sputter Deposition

358. USING DIP-PEN NANOLITHOGRAPHY TOORDER PROTEINS AND COLLOIDS ATSURFACES$420,000DOE Contact: Bharat Agrawal (301) 903-2057LLNL Contact: J. J. DeYoreo (925) 423-4240

The ability to organize nanometer scale species such asquantum dots, proteins, colloids and viruses is emergingas a key area of nanoscience and technology. In thisproject we are using dip-pen nanolithography to patternsurfaces at the nanoscale in order to create templates forassembly of ordered arrays. We are utilizing “inks”covalently bind to the “paper” (i.e., the substrate) and thatensure chemo-selective binding of the target species tothe pattern. By shrinking the pattern to sufficiently smallsize we will be able to assemble single molecules orcolloidal species into well defined arrays. The degree ofordering in those arrays will then be investigated usingsynchrotron methods and the assembly process itself willbe modeled using kinetic Monte Carlo simulations

Keywords: Dip-Pen Nanolithography, Atomic ForceMicroscopy, Templates, NanoscalePatterns

359. PLASMA POLYMER COATING TECHNOLOGYFOR ICF TARGETS$500,000DOE Contact: Bharat Agrawal (301) 903-2057LLNL Contacts: R. Cook (925) 422-3117 and

Steve Letts, (925) 422-0937

This program has as its objective the development of aCH or CD based plasma polymer coating technology toproduce both thin-walled, temperature stable mandrels aswell a smooth 150 µm thick CH or CD ablator coatingresulting in a 2mm diameter capsule target for theNational Ignition Facility (NIF). The approach involvesfirst forming a symmetric 2mm diameter shell mandrelfrom poly(a-methylstyrene) by microencapsulation. Thisis then overcoated with a thin (12-15 µm) layer of CH orCD plasma polymer formed by flowing a feed gas (CH4,C4H6, or deuterated analogs) plus H2 (or D2) through anR/F field to form molecular fragments which coat the shellin a bounce pan. Pyrolysis of the poly(a-methylstyrene) togaseous monomer that diffuses away leaves thespherically symmetric, thermally stable CH or CD shellbehind. Additional coating to 150 µm gives a NIF capsuletarget. The focus of the past year has been improvementof the mandrel surface finish.

Keywords: Polymers, Laser Fusion Targets, PlasmaPolymer, Ablator

Office of Civilian Radioactive Waste Management

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OFFICE OF CIVILIAN RADIOACTIVE WASTE MANAGEMENT

FY 2002

OFFICE OF CIVILIAN RADIOACTIVE WASTE MANAGEMENT - GRAND TOTAL $30,540,000


Waste Packages 30,540,000

Office of Civilian Radioactive Waste Management

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OFFICE OF CIVILIAN RADIOACTIVE WASTE MANAGEMENT


360. WASTE PACKAGES$30,540,000DOE Contact: Paige Russell, (702) 794-1315 and

Kirk Lachman, (702) 794-5096M&O Contacts: Larry Lucas, (702) 295-4414 and

Robert Andrews, (702) 295-5549

The development of the nation’s high-level wasterepository has been delegated to DOE’s Yucca MountainSite Characterization Project Office. Bechtel SAICCompany, the contractor for the Civilian RadioactiveWaste Management System, is responsible for designingthe waste package and related portions of the engineeredbarrier system. The advanced conceptual design wascompleted in 1996 and Viability Assessment design wascompleted in 1998. The current design was selected in1999. Progress on the waste package and the supportingmaterials studies has been documented in variousreports.

The waste package design effort includes thedevelopment of waste packages to accommodateuncanistered commercial spent nuclear fuel(SNF),canistered SNF, canistered defense high-levelwaste, Navy fuel, and other DOE-owned spent nuclearfuel. The analytical process that is underway to supportthese designs included thermal, structural, and neutronic

analyses. Also included are materials selection andengineering development. The current design consists ofa corrosion-resistant outer barrier of Alloy 22 and astainless steel inner shell, which provides structuralsupport. Titanium is still used as the drip shield material.

The waste package materials effort includes the testingand modeling of materials being considered for inclusionin the waste package and the engineered barrier system.These materials include Alloy 22 (UNS# N06022),titanium grade 7, titanium grade 24, and 316 stainlesssteel. The testing includes general aqueous and humidair testing, localized degradation such as pitting andcrevice corrosion, micro-biologically-influenced corrosion,galvanic corrosion, and stress corrosion cracking. Thecorrosion test facility started the long-term test program inFY 1997. Evaluation of five-year specimens will beinitiated in FY 2003. Waste form materials are also beingevaluated for alteration and leaching underrepository-relevant conditions. In 2002 the short-term testprogram was continued to support waste packagematerial degradation model development effort. Theshort-term test program focuses on stress corrosioncracking, crevice corrosion, and passive film stabilityamong the candidate materials.

Keywords: Yucca Mountain Repository, WastePackage, Engineered Barrier System

Office of Fossil Energy

169

OFFICE OF FOSSIL ENERGY

FY 2002

OFFICE OF FOSSIL ENERGY - GRAND TOTAL $10,343,999

OFFICE OF ADVANCED RESEARCH $10,343,999

FOSSIL ENERGY ADVANCED RESEARCH MATERIALS PROGRAM $6,745,999


Mo-Si Alloy Development 300,000Influence of Processing on Microstructure and Properties of Intermetallics 170,000Chemically Vapor Deposited YSZ for Thermal and Environmental Barrier Coatings 225,000Corrosion-Resistant Composite Structures 275,000Extended-Lifetime Metallic Coatings for High-Temperature Environmental Protection 210,000Evaluation of Advanced Pressure Boundary Alloys for Heat Recovery Systems 190,000Intermetallic Reinforced Cr Alloys 110,000Development of Novel Activated Carbon Composites 200,000Corrosion Protection of Ultrahigh Temperature Intermetallic Alloys 200,000CRADAs for Development and Testing of Carbon Materials 150,000CRADA on Advanced Austenitic Alloys 50,000CRADA on Thermie Alloy Processing 70,000Development of VLS Scaling Parameters for Production of Silicon Carbide Fibrils 125,000Metallic Coatings for Power-Generation Applications 85,000Modeling of CVD for Solid State Electrolytes 90,000


Development of NDE Methods for Structural Ceramics 175,000Corrosion and Mechanical Properties of Alloys in FBC and Mixed-Gas Environments 175,000Investigation of the Weldability of Intermetallics 70,000In-Plant Corrosion Probe Tests of Advanced Austenitic Alloys 80,000Investigation of Weld Overlays and Coatings 100,000Oxide Dispersion Strengthened (ODS) Alloys 230,000Concepts for Smart Protective High-Temperature Coatings 70,000Reduction of Defect Content In ODS Alloys 100,000Support Services for Ceramic Hot-Gas Filters and Heat Exchangers 100,000Intrinsic and Extrinsic Fracture Behavior of Intermetallic Compounds 60,000


Metallic Filters for Hot-Gas Cleaning 90,000Refractory Materials Issues in Gasifiers 100,000Development of Ceramic Membranes for Hydrogen Separation 350,000Production of Pure Hydrogen from Hydrocarbons 100,000Materials and Components in Fossil Energy Applications Newsletter 60,000High-Temperature Materials Testing in Coal Combustion Environments 200,000Improved Membrane Materials and Economical Fabrication 225,000Management of Advanced Research Materials Program 400,000Membrane Seal Development, Characterization, and Testing 450,000Personal Services Contract 20,000Development of ODS Alloy for Heat Exchanger Tubing 160,000Molecular Sieves for Hydrogen Separation 150,000Microscopic and Microstructural Issues for Optimal Material Design 100,000Fatigue and Fracture Behavior of Cr-X Alloys 75,000


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OFFICE OF FOSSIL ENERGY (continued)

FY 2002

FOSSIL ENERGY ADVANCED RESEARCH MATERIALS PROGRAM (continued)

ULTRA-SUPERCRITICAL STEAM POWER PLANT RESEARCH $550,000

Ultra-Supercritical Steam Turbine Materials 200,000Materials for Ultra-Supercritical Steam Power Plants 0Ultra-Supercritical Steam Cycle Turbine Materials 350,000

VISION 21 SUPPORT ACTIVITIES $105,999

Improved ODS Alloy for Heat Exchanger Tubing 105,999

ADVANCED METALLURGICAL PROCESSES PROGRAM $3,598,000


Advanced Foil Lamination Technology 560,000Advanced Casting Technologies 400,000


Advanced Refractories for Gasifiers 600,000Oxidation and Sulfidation Resistant Materials 600,000Wear and Abrasion of Materials for Fossil Energy Systems 600,000Mechanisms of Corrosion Under Ash Deposits 550,000Non-Isothermal Corrosion and Oxidation 288,000


171

OFFICE OF FOSSIL ENERGY

The Office of Fossil Energy responsibilities include management of the Department's fossil fuels (coal, oil, and natural gas)research and development program. This research is generally directed by the Office of Coal Technology, the Office of Gasand Petroleum Technology, and the Office of Advanced Research and Special Technologies in support of the NationalEnergy Strategy Goals for Increasing Energy Efficiency, Securing Future Energy Supplies, Respecting the Environment, andFortifying our Foundations. Three specific fossil energy goals are currently being pursued:

1) The first is to secure liquids supply and substitution. This goal targets the enhanced production of domestic petroleumand natural gas, the development of advanced, cost-competitive alternative fuels technology, and the development ofcoal-based, end-use technology to substitute for oil in applications traditionally fueled by liquid and gaseous fuel forms.

2) The second is to develop power generation options with environmentally superior, high-efficiency technologies for theutility, industrial, and commercial sectors. This goal targets the development of super-clean, high-efficiency powergeneration technologies.

3) The third is to pursue a global technology strategy to support the increased competitiveness of the U.S. in fossil fueltechnologies, to maintain world leadership in our fossil fuel technology base, and provide expanded markets for U.S.fuels and technology. This crosscutting goal is supported by the activities in the above two technology goals.

OFFICE OF ADVANCED RESEARCH

FOSSIL ENERGY ADVANCED RESEARCH MATERIALS PROGRAM

Fossil Energy materials-related research is conducted under the Advanced Research Materials Program. The goal of theFossil Energy Advanced Research Materials Program is to provide a materials technology base to assure the success ofcoal fuels and advanced power generation systems being pursued by DOE-FE. The purpose of the Program is to developthe materials of construction, including processing and fabrication methods, and functional materials necessary for thosesystems. The scope of the Program addresses materials requirements for all fossil energy systems, including materials forcoal fuels technologies and for advanced power generation technologies such as coal gasification, heat engines, combustionsystems, and fuel cells. The Program is aligned with the development of those technologies that are potential elements ofthe DOE-FE Vision 21 concept, which aims to address and solve environmental issues and thus remove them as aconstraint to coal's continued status as a strategic resource.

The principal development efforts of the Program are directed at ceramic composites for high-temperature heat exchangerapplications; new corrosion- and erosion-resistant alloys with unique mechanical properties for advanced fossil energysystems; functional materials such as metal and ceramic hot-gas filters, gas separation materials based on ceramicmembranes (porous and ion transport), fuel cells, and activated carbon materials; and corrosion research to understand thebehavior of materials in coal-processing environments. In cooperation with DOE-ORO, Oak Ridge National Laboratory hasthe responsibility of the technical management and implementation of all activities on the DOE Fossil Energy AdvancedResearch Materials Program. DOE-FE administration of the Program is through the National Energy Technology Laboratoryand the Advanced Research Product Team.


361. Mo-Si ALLOY DEVELOPMENT$300,000DOE Contacts: F. M. Glaser (301) 903-2784,

V. U. S. Rao (412) 386-4743, M. H. Rawlins(865) 576-4507

Oak Ridge National Laboratory Contact: J. H. Schneibel (865) 574-4644

Ames Laboratory Contact: M. J. Kramer (515) 294-0276

The objective of this task is to develop new generationcorrosion resistant Mo-Si alloys for use as hot

components in advanced fossil energy conversion andcombustion systems. The successful development of Mo-Si alloys is expected to improve the thermal efficiencyand performance of fossil energy conversion systemsthrough increased operating temperatures, and toincrease the service life of hot components exposed tocorrosive environments at temperatures as high as1600/C. This effort thus contributes directly to Vision 21,one goal of which is to significantly reduce greenhouseemissions. The effort focuses presently on Mo-Si-B alloyscontaining high volume fractions of molybdenum silicidesand borosilicides.

Keywords: Alloys, Molybdenum, Silicon


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362. INFLUENCE OF PROCESSING ONMICROSTRUCTURE AND PROPERTIES OFINTERMETALLICS $170,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: I. G. Wright (865) 574-4451

Idaho National Engineering and EnvironmentalLaboratory Contact: R. N. Wright(208) 526-6127

The objective of this program is to develop techniques forprocessing advanced alloys for fossil energy applicationsto improve elevated temperature mechanical propertiesand resistance to environmental degradation. Extensivework has been performed in cooperation with the effortsat ORNL on development: of aluminide alloys forstructural applications. Significant progress has beenmade on improving the ambient temperature ductility andcreep properties of these alloys. It has been determinedthat much of the benefit of environmental resistance fromthese alloys could be obtained from coatings. Results onthe relationship of processing to microstructure,properties and performance of iron aluminides will beextended to coatings for protection of structural alloysfrom environmental degradation. Advanced in situdiagnostics will be employed to determine the relationshipof particle characteristics size, temperature and velocityduring thermal spray deposition to the observed residualstress and microstructure. The environmental resistanceof these well characterized coatings to high temperatureatmospheres of interest to fossil energy applications willbe determined in collaboration with ORNL. Coatingsynthesis and performance characteristics of otheradvanced alloys, e.g., Mo-Si- and chromia-forming alloyswill also be examined.

Keywords: Aluminides, Processing, Microstructure

363. CHEMICALLY VAPOR DEPOSITED YSZ FORTHERMAL AND ENVIRONMENTAL BARRIERCOATINGS$225,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: T. M. Besmann (865) 574-6852

The purpose of this task is to develop a chemical vapordeposition (CVD) process for fabricating yttria-stabilizedzirconia (YSZ) for thermal and environmental barrierapplications. YSZ has been the phase of choice forthermal barrier coating (TBC) applications due to its lowthermal conductivity and high thermal stability. The CVDprocess being explored utilizes organometallic precursors

flowing over a heated substrate in a flow reactor. Acurrent technology for thermal barrier coatings (TBCs) forhigh-performance turbine blades utilizes electron-beamphysically vapor deposited (EBPVD) yttria-stabilizedzirconia (YSZ). The deposits are columnar in nature,resulting in excellent strain tolerance during thermalcycling. There exist, however, a number of issues withregard to cost, long-term stability, and environmentaldegradation of these coatings. The CVD process for YSZis being developed for consideration as a replacement forthe capital intensive EBPVD process, as a supplement toEBPVD to coat regions that the line-of-sight processcannot reach, and as a seal coat (environmental barriercoating or EBC) for EBPVD layers.

Keywords: Composites, Ceramics, Coatings

364. CORROSION-RESISTANT COMPOSITESTRUCTURES$275,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: B. A. Armstrong (865) 241-5862

The purpose of this program is to develop ceramiccoatings with enhanced corrosion resistance throughimprovements in the composition and processing of thecoating. Processing innovations will focus on aqueouscoating development including such techniques as spraycoating, dip coating and vacuum infiltration. Approachesto coatings, such as mullite, that have shown goodcorrosion resistance and materials that form scales otherthan silica will be evaluated. Candidate materials will beexposed in facilities at ORNL, the DOE National EnergyTechnology Laboratory, and the University of NorthDakota Energy and Environmental Research Center. Allspecimens will be characterized at ORNL to identify themost promising materials for specific applications.

Keywords: Composites, Ceramics, Fiber-Reinforced,Corrosion

365. EXTENDED-LIFETIME METALLIC COATINGSFOR HIGH-TEMPERATURE ENVIRONMENTALPROTECTION$210,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: P. F. Tortorelli (865) 574-5119

The purpose of this task is to examine importantcomposition and microstructure issues associated withthe development of extended-lifetime corrosion-resistantmetallic coatings for high-temperature applications


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associated with the key technologies of the Office ofFossil Energy’s Vision 21 concept.

Keywords: Coatings, Corrosion

366. EVALUATION OF ADVANCED PRESSUREBOUNDARY ALLOYS FOR HEAT RECOVERYSYSTEMS $190,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: R. W. Swindeman (865) 574-5108

The purpose of this task is to evaluate structural alloys forimproved performance of high-temperature componentsin advanced combined-cycle and coal-combustionsystems with emphasis on cycles at temperatures of750/C and higher.

Keywords: Materials, Mechanical Properties,Austenitics, Hot-Gas

367. INTERMETALLIC REINFORCED Cr ALLOYS$110,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contacts: M. P. Brady (865) 574-5153

The objective of this task is to develop high-strength,oxidation- and corrosion-resistant metallic andintermetallic alloys for use as hot components inadvanced fossil energy conversion and combustionsystems to help meet the efficiency and clean powergeneration goals of Vision 21. These alloys are needed toimprove thermal efficiency through increased operatingtemperatures and decreased cooling requirements, aswell as to provide materials for applications ranging fromprocess monitoring (e.g., thermowells) to structuralcomponents or protective coatings in aggressiveenvironments such as those encountered in coalgasification systems (e.g. molten salt, slag, ash, etc.).The development effort is based on increasingperformance through fundamental understanding,manipulation, and control of multi-phase metallic(including intermetallic) structures. The effort will initiallybe devoted to in-situ composite alloys based on a Crsolid solution matrix reinforced with intermetallic Cr2X (X= Nb, Ta, Y) Laves phases. A major goal of this programwill be to transition the advances made in identifying,understanding and developing new families of high-performance multi-phase alloys to applied spin-off effortsdevoted to further alloy/coating development and

optimization for specific energy conversion andcombustion system applications and components.

Keywords: Alloys, Chromium-Niobium, Corrosion,Intermetallic Compounds

368. DEVELOPMENT OF NOVEL ACTIVATEDCARBON COMPOSITES$200,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: T. D. Burchell (865) 576-8595

There is increasing interest in the separation of CO2 froma variety of gas streams and for a variety of purposes.The separations include the removal of CO2 from gasturbine exhaust gas streams for subsequent disposal(e.g., by injection into an oil well for enhanced oilrecovery), or the removal of CO2 from the fuel andoxidant streams of fuel cells. Moreover, natural gasfrequently contains large fractions of diluents andcontaminants such as CO2 and H2S. Carbon FiberComposite Molecular Sieves (CFCMS) materials will bedeveloped to effect the separation of diluents andcontaminants from natural gas. Additionally, H2O must beremoved from natural gas to minimize pipeline corrosion.The purpose of this work is to develop carbon molecularsieves (CMS) starting with porous Carbon FiberComposites (CFC) manufactured from petroleum pitchderived carbon fibers. The CFCMS will be utilized inPressure Swing Adsorption (PSA) units or ElectricalSwing Adsorption (ESA) units for the efficient recovery ofCO2 from gas mixtures. Novel separation techniques, thatexploit the unique combination of properties of CFCMS,will be developed to effect the above mentionedseparations.

Keywords: Carbon Fibers, Sieves, Composites

369. CORROSION PROTECTION OF ULTRAHIGHTEMPERATURE INTERMETALLIC ALLOYS$200,000DOE Contacts: F. M. Glaser (301) 903-2784,



The objective of this task is to develop high-strength,oxidation- and corrosion-resistant metallic andintermetallic alloys for use as hot components inadvanced fossil energy conversion and combustionsystems to help meet the efficiency and clean powergeneration goals of Vision 21. These alloys are needed toimprove thermal efficiency through increased operatingtemperatures and decreased cooling requirements, as


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well as to provide materials for applications ranging fromprocess monitoring (e.g. thermowells) to structuralcomponents or protective coatings in aggressiveenvironments such as those encountered in coalgasification systems (e.g. molten salt, slag, ash, etc.).The development effort is based on increasingperformance through fundamental understanding,manipulation, and control of multi-phase metallic(including intermetallic) structures. The effort will initiallybe devoted to in-situ composite alloys based on a Crsolid solution matrix reinforced with intermetallic Cr2X (X= Nb, Ta, Y) Laves phases. A major goal of this programwill be to transition the advances made in identifying,understanding and developing new families of high-performance multi-phase alloys to applied spin-off effortsdevoted to further alloy/coating development andoptimization for specific energy conversion andcombustion system applications and components.


370. CRADAS FOR DEVELOPMENT AND TESTINGOF CARBON MATERIALS$150,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: T. D. Burchell (865) 576-8595

Hydrogen and methane gas recovery technologies arerequired to: 1) allow the upgrading of heavyhydrocarbons to transport fuels, thus reducing theamount of carbon rejected during crude oil refining and 2)improve the yield and process economics of natural gaswells. The purpose of this work is to develop carbon fibercomposite molecular sieves (CFCMS) from porouscarbon fiber composites manufactured from solventextracted coal tar pitch derived carbon fibers. Keywords: Carbon Products

371. CRADA ON ADVANCED AUSTENITIC ALLOYS$50,000DOE Contacts: F. M. Glaser (301) 903-2784,



The purpose of this task is to engage in cooperative workwith an industrial firm on the development of advancedaustenitic alloys.

Keywords: Alloys, Austenitics, Technology Transfer

372. CRADA ON THERMIE ALLOY PROCESSING$70,000DOE Contacts: F. M. Glaser (301) 903-2784,



The purpose of this task is cooperative work with SpecialMetals Corporation to develop the processing technologyfor Thermie alloy.

Keywords: Alloys, Technology Transfer

373. DEVELOPMENT OF VLS SCALINGPARAMETERS FOR PRODUCTION OF SILICONCARBIDE FIBRILS$125,000DOE Contacts: F. M. Glaser (301) 903-2784,



ReMaxCo Technologies, Inc. Contact: R. D. Nixdorf (865) 483-5060

The DOE Fossil Energy Program has an interest insilicon carbide fibrils as a material for high-temperatureheat exchanger and recuperation components inadvanced coal combustion plants. The purpose of thisproject is to develop a commercial process for theproduction of silicon carbide fibrils. The slow growth ofthe fibrils and excessive waste of raw materials havebeen the major impediments. This work is an effort tobring new technology solutions to the future volumeproduction of silicon carbide fibrils.

Keywords: Ceramics, Composites, Fibrils, Modeling

374. METALLIC COATINGS FOR POWER-GENERATION APPLICATIONS$85,000DOE Contacts: F. M. Glaser (301) 903-2784,



Tennessee Technological University Contact: Ying Zhang (931) 372-3186

The purpose of this task the fabrication, characterizationand testing of aluminide coatings made on ferritic alloyssuch as Fe-9Cr-1Mo steels, which are being consideredfor use in advanced steam cycles. In addition, theinfluences of duty cycle length and operating temperature


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on the oxidation behavior of state-of-the-art bondcoatings for fossil-fueled turbine engines are investigated.


375. MODELING OF CVD FOR SOLID STATEELECTROLYTES$90,000DOE Contacts: F. M. Glaser (301) 903-2784,



University of Louisville Contact: T. L. Starr (502) 852-1073

There are two critical requirements for successful,ambient pressure CVD of solid oxide electrolyte films:maintain uniformity in thickness and composition over areasonably large substrate, and avoid gas-phasenucleation that degrades film quality. The proposedresearch addresses both requirements and is based onthe unique characteristics of stagnation point flow.

Stagnation point flow describes the characteristics of afluid stream impinging upon a planar substrate. With thisgeometry, modeling of mass and energy transportbetween the stream and the substrate surface can bereduced to a one-dimensional, boundary layer problem.Further, with proper selection of flow conditions, theeffective boundary layer thickness is essentially uniformover an appreciable portion of the substrate. Also, byutilizing a cold-wall design—cool stream impinging on aheated substrate—the “residence time at temperature” forthe stream is small, minimizing gas phase reactions.

This project shall investigate the application of stagnationpoint flow to the deposition of yttrium-stabilized zirconia(YSZ) solid electrolyte films, including an experimentaleffort at ORNL and a modeling effort at the University ofLouisville.

Keywords: Ceramics, Composites, Modeling, FuelCells


376. DEVELOPMENT OF NONDESTRUCTIVEEVALUATION METHODS FOR STRUCTURALCERAMICS$175,000DOE Contacts: F. M. Glaser (301) 903-2784,



Argonne National Laboratory Contact:W. A. Ellingson (630) 252-5068

The purpose of the work in this project is to developnondestructive evaluation (NDE) technology as part ofthe overall effort to develop high temperature materialsfor advancing utilization of fossil fuel resources. This workfocuses on advanced structural and functional materialsused to foster clean utilization of coal. These new high-temperature materials, which are an enabling technology,will allow coal to be utilized in a more environmentallyacceptable manner. Examples of high-temperatureceramics include high-temperature 02 and H2 separationmembranes and thermal barrier coatings for first-stagehot-section blades and vanes in combustion turbines.The NDE technology provides end users with reliabledata on which to make cost-effective decisions aboutwhether to replace a component or allow a component toremain in service. In addition, the NDE data may becoupled with models for predicting the remaining life of aparticular component.

Keywords: Nondestructive Evaluation, Ceramics,Flaws, Fracture

377. CORROSION AND MECHANICAL PROPERTIESOF ALLOYS IN FBC AND MIXED-GASENVIRONMENTS$175,000DOE Contacts: F. M. Glaser (301) 903-2784,



Argonne National Laboratory Contact: K. Natesan(630) 252-5103

The purposes of this task are: 1) to evaluate thecorrosion performance of materials in simulatedcombustion environments for application in advancedsteam-cycle systems, 2) to evaluate the role of depositscontaining sulfur and/or chlorine and ash constituents in


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the corrosion behavior of metallic alloys, selectedcoatings, and monolithic/composite ceramics, 3) toevaluate the residual mechanical properties of materialsafter exposure in corrosive environments and quantify theeffects of corrosion on the properties to enable lifeprediction of components, and 4) to expose candidatealloys, coatings, weldments, and ceramics in small-scalecombustion test facilities at the NETL and the Universityof North Dakota Energy and Environmental ResearchCenter.

Keywords: Corrosion, Gasification, Creep Rupture,Fluidized-Bed Combustion

378. INVESTIGATION OF THE WELDABILITY OFINTERMETALLICS$70,000DOE Contacts: F. M. Glaser (301) 903-2784,



Colorado School of Mines Contact: G. R. Edwards(303) 273-3773

The purpose of this project is the investigation of theweldability of polycrystalline aluminides. The major thrustof the project is to determine the role of microstructure inthe intergranular cracking of aluminides, with specialemphasis on weld cracking susceptibility. The weldabilityof polycrystalline Fe3Al-X alloys is being evaluated, andthe weldability is correlated with composition, phaseequilibria, grain size and morphology, domain size, anddegree of long-range order.

Keywords: Joining, Welding

379. IN-PLANT CORROSION PROBE TESTS OFADVANCED AUSTENITIC ALLOYS$80,000DOE Contacts: F. M. Glaser (301) 903-2784,



Foster Wheeler Development Corporation Contact:J. L. Blough (201) 535-2355

The purpose of this project is to provide comprehensivecorrosion data for selected advanced austenitic tubealloys in simulated coal ash environments. ORNL-modified alloys and standard comparison alloys havebeen examined. The variables affecting coal ashcorrosion and the mechanisms governing oxidebreakdown and corrosion penetration are beingevaluated. Corrosion rates of the test alloys aredetermined as functions of temperature, ash composition,gas composition, and time.

Keywords: Austenitics, Alloys, Corrosion

380. INVESTIGATION OF WELD OVERLAYS ANDCOATINGS$100,000DOE Contacts: F. M. Glaser (301) 903-2784,



Lehigh University Contact: A. R. Marder (610) 758-4197

The objective of this activity is the investigation of ironaluminide weld overlays. Specific tasks include: 1) fillerwire development 2) weldability 3) oxidation andsulfidation studies 4) erosion studies 5) erosion-corrosion studies, and 6) field exposures.

Keywords: Alloys, Aluminides, Overlay, Welding,Joining

381. OXIDE DISPERSION STRENGTHENED (ODS)ALLOYS$230,000DOE Contacts: F. M. Glaser (301) 903-2784,



The purpose of this task is to address the materialsrelated barriers to expediting the use of oxide dispersionstrengthened (ODS) alloys in components required inDOE's Office of Fossil Energy Vision 21 processes tooperate at temperatures higher than are possible withconventionally strengthened alloys. Specific goals are todevelop a detailed understanding of the behavior of ODSalloys in all phases of their use, including fabrication,service performance, life prediction, mode of failure,repair, and refurbishment. The scope of the effortincludes the development of ODS iron aluminum alloysthat combine strength levels of the same order ascommercially available ODS FeCrAl alloys, with thesuperior resistance to high temperature sulfidation andcarburization attack demonstrated by the best ironaluminides.

Keywords: Aluminides

382. CONCEPTS FOR SMART PROTECTIVE HIGH-TEMPERATURE COATINGS$70,000DOE Contacts: F. M. Glaser (301) 903-2784,



The overall purpose of this work is to assess thefeasibility of different material and design approaches tosmart protective coatings by exploring new alloying and


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microstructural approaches to improved high-temperatureenvironmental resistance of metallic components.


383. REDUCTION OF DEFECT CONTENT IN ODSALLOYS$100,000DOE Contacts: F. M. Glaser (301) 903-2784,



The University of Liverpool Contact: A. R. Jones151-794-8026

The purpose of this work is to assess the sources ofdefects in oxide-dispersion-strengthened (ODS) alloys.Experiments to confirm key features of defects in ODSalloys shall be devised and performed, andrecommendations shall be made for the reduction ofdefects in these alloys.

Keywords: Aluminides, Defects

384. SUPPORT SERVICES FOR CERAMIC HOT-GASFILTERS AND HEAT EXCHANGERS$100,000DOE Contacts: F. M. Glaser (301) 903-2784,



University of North Dakota Energy andEnvironmental Research Center (UNDEERC)Contact: J. P. Hurley (701) 777-5159

This task will review and, if appropriate, proposemodifications to plans, materials, and tests planned byresearchers on the Advanced Research MaterialsProgram in work to test materials for coal-fueled energysystems. The changes shall be suggested in order tomake the corrosion experiments more reflective of theactual conditions that will be encountered by thematerials in the energy systems. UNDEERC shallaccomplish this task by reviewing the major advancedenergy system projects being funded by the DOE, and byworking with the company's technical monitor and staff toprepare a summary of the expected corrosion problems.Both gasification and combustion systems will beincluded. Ceramic materials in two subsystems will be thefocus of this work: 1) hot gas cleanup systems and2) high-temperature heat exchangers. UNDEERC shallreview and suggest improvements to materials testingprocedures that are used to determine material behaviorwhen used in hot-gas cleanup or heat exchangerapplications. A limited amount of computer modeling andlaboratory experimentation shall be a part of this effort.

Keywords: Composites, Ceramics, Fibers

385. INTRINSIC AND EXTRINSIC FRACTUREBEHAVIOR OF INTERMETALLIC COMPOUNDS$60,000DOE Contacts: F. M. Glaser (301) 903-2784,



West Virginia University Contact: B. R. Cooper(304) 293-3423

The purpose of this activity is the evaluation of theintrinsic and extrinsic fracture behavior of iron aluminidesand the study of atomistic simulations of defectconcentrations, dislocation mobility, and solute effects inFe3Al. The work also involves an experimental study ofenvironmentally-assisted crack growth of Fe3Al at roomand at elevated temperatures. The combined modelingand experimental activities are expected to elucidate themechanisms controlling deformation and fracture in Fe3Alin various environments.

Keywords: Alloys, Aluminides, Fracture


386. METALLIC FILTERS FOR HOT-GAS CLEANING$90,000DOE Contacts: F. M. Glaser (301) 903-2784,


Ames Laboratory Contact: Iver Anderson (515) 294-4446

The objective of this study is to design and developmetallic filters having uniform, closely controlled porosityusing a unique spherical powder processing and sinteringtechnique. The corrosion resistance of the filter materialswill be evaluated under simulated PFBC/IGCC gaseousenvironments in order to determine the optimum alloycomposition and filter. structure. The corrosion tests willalso provide a means to estimate the service lives ofexperimental filter materials when subjected to eithernormal or abnormal PFBC/IGCC plant operatingconditions. Metallic filters are expected to offer thebenefits of non-brittle mechanical behavior and improvedresistance to thermal fatigue compared to ceramic filterelements, thus improving filter reliability. Moreover, thebinder-assisted powder processing and sinteringtechniques to be developed in this study will permitadditional filter design capability (e.g., highly controlledfilter porosity/permeability with greatly enhancedprocessing simplification), thus enabling more efficientand effective filtration.

Keywords: Filters


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387. REFRACTORY MATERIALS ISSUES INGASIFIERS$100,000DOE Contacts: F. M. Glaser (301) 903-2784, V. U. S. Rao (412) 386-4743, M. H. Rawlins

(865) 576-4507 Albany Research Center Contact:

Richard P. Walters (541) 967-5873

The purpose of this research is to characterize andunderstand slag component interactions with therefractories used in coal gasifiers. It is anticipated thatonce these interactions are understood, it will be possibleto find a means of controlling, i.e., limiting, the slag-refractory interactions and extending the refractorylifetime.

Keywords: Refractories

388. DEVELOPMENT OF CERAMIC MEMBRANESFOR HYDROGEN SEPARATION$350,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: R. R. Judkins (865) 574-4572

The purpose of this activity is to fabricate inorganicmembranes for the separation of gases at hightemperatures and/or in hostile environments, typicallyencountered in fossil energy conversion processes suchas coal gasification. This work is performed in conjunctionwith a separate research activity that is concerned withthe development and testing of the ceramic membranes.

Keywords: Ceramics, Membranes, Filters, Separation

389. PRODUCTION OF PURE HYDROGEN FROMHYDROCARBONS$100,000DOE Contacts: F. M. Glaser (301) 903-2784,


Los Alamos National Laboratory Contact: Steven A. Birdsell (505) 667-5868

The palladium membrane reactor was developed forprocessing tritiated water and tritiated hydrocarbonsfound in fusion energy, weapons and environmentalapplications. In addition to these applications, the PMRhas the potential to revolutionize fossil fuel processing.However, in order to use the PMR in fuel applications,further performance data and development are needed. Astate-of-the art PMR employing a thin palladium (Pd) filmcomposite membrane will be used to evaluateperformance and determine the best operating conditionsfor production of pure hydrogen from coal gas. Simulatedcoal-gas processing has been done at higher pressures(> 200 psig). Real coal gas contains impurities such as

sulfur that are potentially poisonous to PMRs. This effectwill need to be determined. Also, in order to make thetechnology practical for industrial use, a higher flux Pdmembrane is needed. Such a membrane has beendeveloped at Los Alamos. An advanced PMR will beconstructed with the high-flux membrane and tested withsimulated coal gas. Successful demonstration of theadvanced PMR could lead to a radical decrease in thecost of fossil fuel processing. The purpose of this projectis to develop palladium membrane reactor (PMR)technology for production of hydrogen from coal gas.

Keywords: Membranes

390. MATERIALS AND COMPONENTS IN FOSSILENERGY APPLICATIONS NEWSLETTER$60,0001

DOE Contacts: F. M. Glaser (301) 903-2784, V. U. S. Rao (412) 386-4743, M. H. Rawlins(865) 576-4507


The purpose of this task is to publish a bimonthly, jointDOE-EPRI newsletter to address current developmentsin materials and components in fossil energyapplications.

Keywords: Materials, Components

391. HIGH-TEMPERATURE MATERIALS TESTING INCOAL COMBUSTION ENVIRONMENTS$200,000DOE Contacts: F. M. Glaser (301) 903-2784,


National Energy Technology Laboratory Contact:Anthony V. Cugini (412) 892-6023

Structural and functional materials used in solid- andliquid-fueled energy systems are subject to gas- andcondensed-phase corrosion, and erosion by entrainedparticles. The material temperature and composition ofthe corrodents determine the corrosion rates, while gasflow conditions and particle aerodynamic diametersdetermine erosion rates for a given material. Corrodentcomposition depends on the composition of the fuel, thetemperature of the material, and the size range of theparticles being deposited. It is difficult to simulate undercontrolled laboratory conditions all of the possiblecorrosion and erosion mechanisms to which a materialmay be exposed in an energy system. Therefore, theUniversity of North Dakota Energy & EnvironmentalResearch Center and the U.S. Department of Energy,National Energy Technology Laboratory are working withOak Ridge National Laboratory to provide materials

1Matching funding provided by EPRI.


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scientists with no-cost opportunities to expose materialsin pilot-scale systems to conditions of corrosion anderosion similar to those in occurring in commercial powersystems.

NETL is operating the Combustion and EnvironmentalResearch Facility (CERF). In recent years, the 0.5MMBtu/hr CERF has served as a host for exposure ofover 60 ceramic and alloy samples at ambient pressureas well as at 200 psig (for tubes). Samples have beeninserted in five locations covering 1700-2600ºF, withexposures exceeding 1000 hours. In the presentprogram, the higher priority metals are to be tested at1500-1600ºF in one CERF location and near 1800-2000ºF at other locations to compare results with thosefrom the EERC tests.

Keywords: Testing

392. IMPROVED MEMBRANE MATERIALS ANDECONOMICAL FABRICATION$225,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: T. R. Armstrong (865) 574-7996

The purpose of this task is to develop infrared plasmaprocessing as a method to rapidly sinter membranematerials such as yttria stabilized zirconia (YSZ, for fuelcells) and barium cerate (for hydrogen separation). Thisprocess will fully evaluate and determine the feasibility ofthis process for sintering YSZ and barium cerate filmsdeposited by screen printing on green and pre sinteredsupport structures. The goal of this process is to reducedcycle times and costs for membrane fabrication. Inaddition, this task will start pursuing development of novelapproach for the fabrication of asymmetric membranes.

Keywords: Membranes

393. MANAGEMENT OF THE ADVANCEDRESEARCH MATERIALS PROGRAM$400,000DOE Contacts: F. M. Glaser (301) 903-2784,



The goal of the Fossil Energy Advanced ResearchMaterials Program is to provide a materials technologybase to assure the success of coal fuels and advancedpower generation systems being pursued by DOE-FE.The purpose of the Program is to develop the materials ofconstruction, including processing and fabricationmethods, and functional materials necessary for thosesystems. The scope of the Program addresses materialsrequirements for all fossil energy systems, including

materials for coal fuels technologies and for advancedpower generation technologies such as coal gasification,heat engines, combustion systems, and fuel cells. TheProgram is aligned with the development of thosetechnologies that are potential elements of the DOE-FEVision 21 concept, which aims to address and solveenvironmental issues and thus remove them as aconstraint to coal's continued status as a strategicresource.

The principal development efforts of the Program aredirected at ceramic composites for high-temperature heatexchanger applications; new corrosion- anderosion-resistant alloys with unique mechanicalproperties for advanced fossil energy systems; functionalmaterials such as metal and ceramic hot-gas filters, gasseparation materials based on ceramic membranes(porous and ion transport), fuel cells, and activatedcarbon materials; and corrosion research to understandthe behavior of materials in coal-processingenvironments. In cooperation with DOE-ORO, Oak RidgeNational Laboratory (ORNL) has the responsibility of thetechnical management and implementation of allactivities on the DOE Fossil Energy Advanced ResearchMaterials Program. DOE-FE administration of theProgram is through the National Energy TechnologyLaboratory and the Advanced Research Product Team.

Keywords: Management, Materials Program

394. MEMBRANE SEAL DEVELOPMENT,CHARACTERIZATION, AND TESTING$450,000DOE Contacts: F. M. Glaser (301) 903-2784,



Pacific Northwest National Laboratory Contact: S. K. Weil (509) 375-6796

The purpose of this project is to develop the enablingsealing technology for high efficiency, low emissionsfossil energy conversion, in support of the DOE-Office ofFossil Energy's Clean Coal Utilization and Vision 21programs. Specifically, this project will focus developingthe seals that are required to hermetically join inorganicmembranes used in high temperature gas separation tothe underlying support structure of the separationsystem. The seal materials must not only be compatiblewith both the: membrane and support materials, but mustalso be physically and chemically stable at thetemperatures, pressures, gas atmospheres, and thermalcycling conditions typical of the electrochemicalseparation processes employed with gasified coal andair. The types of membrane materials that are beingdeveloped by the Office of Fossil Energy includemicroporous alumina and cerate-based perovskites forthe separation of hydrogen from coal gas and syngas andtransition metal oxide perovskites and brown millerites for


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the separation of oxygen from air. If successful, thisproject will aid in the deployment of these inorganicmembranes to extract and utilize clean hydrogen fromcoal and will also establish the underlying technical basisrequired to evaluate the multiple approaches to inorganicmembrane developmentthat are currently being pursued.

Keywords: Membranes Testing, Seals

395. PERSONAL SERVICES CONTRACT$20,000DOE Contacts: F. M. Glaser (301) 903-2784,


Oak Ridge National Laboratory Contact: P. T. Carlson (865) 574-5135

The task provides funds for a personal servicessubcontract for services related to the preparation ofexhibits for and the management of exhibits at externalconferences.

Keywords: Conference, Exhibits

396. DEVELOPMENT OF ODS ALLOY FOR HEATEXCHANGER TUBING$160,000DOE Contacts: F. M. Glaser (301) 903-2784,



Special Metals Corporation Contact: Mark Harper(304) 526-5057

This work is intended to generate information andunderstanding for incorporation into a database beinggenerated by the team assembled by Special MetalsCorporation to allow oxide dispersion-strengthened(ODS) alloys to be used in the design, construction, andoperation of heat exchangers in the very high-temperature environments of interest in Vision 21 powerplant modules. This effort has three main objectives:firstly, to characterize the effectiveness of modifiedprocessing routes aimed at optimizing the mechanicalproperties of the ODS-FeCrAl alloy INCO® MA956 forapplication as tubing. Property measurements from thisactivity will form part of the data package required forsubmission of a case for obtaining ASME Boiler andPressure Vessel Code qualification for this alloy.Secondly, to evaluate the available techniques for joiningODS alloys, to provide a sound basis for fabricationoptions. The third objective is to develop a basis forservice lifetime prediction based on the high-temperatureoxidation behavior of this alloy.

Keywords: Alloys, Tubing

397. MOLECULAR SIEVES FOR HYDROGENSEPARATION$150,000DOE Contacts: F. M. Glaser (301) 903-2784,


Sandia National Laboratories Contact: Anthony Martino (505) 844-3332

The purpose of this program is to develop and test threenovel inorganic-organic materials for hydrogen separationand purification. The program will combine experimentaland theoretical efforts to develop and test the followingthree materials as the working thin film in asymmetricInterfacial composite membranes (on alumina supports):In situ generated bridged polysilsesquioxanes, organictemplated silicates and catalytic membranes. 1) Bridgedpolysilsesquioxanes belong to a class of hybrid organic-inorganic materials with thermal stability to 500°C andresistance to acids, strong bases and organic solvents.The organic bridging group can be varied to give anenormous range of materials with differing physical andchemical properties, including hydrogen permeation2) Organic templated silicates are designed to exhibitgreater thermal and chemical stability while still formingthe molecular sieving layer in asymmetric membranes.These materials are prepared from silane precursorswhose organic group chemically reacts during themembrane formation to generate the membrane. 3) Wewill team these synthetic strategies with catalystsyntheses such as micelle-mediated preparation of metalnanoclusters to generate a revolutionary catalystseparation system combining highly dispersed metalnanoclusters in hybrid membranes with preciselymodulated permselectivity. These catalytic membraneswill provide a technology to perform reactions such ashydrogen reforming and the water shift reaction on-line.Pure hydrogen is removed from the reaction zone with asubsequent advantage to the reaction equilibrium.

Keywords: Membranes

398. MICROSCOPIC AND MICROSTRUCTURALISSUES FOR OPTIMAL MATERIAL DESIGN$100,000DOE Contacts: F. M. Glaser (301) 903-2784,



University of California at San Diego Contact: B. K. Kad (619) 534-7059

The objective of this work is to explore experimental andcomputational means by which inherent material andprocessing-induced anisotropies of ODS Fe3Al-basealloys can be exploited to meet in-service mechanicaland creep-life requirements of the power generationindustry. The research shall examine microscopic andmicrostructural issues with a view to addressing optimum


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material design for macroscopic components under wellprescribed in-service loading criteria. The economicincentive is the low cost of Fe3Al-based alloys and itssuperior sulfidation resistance, in comparison to thecompeting Fe-Cr-Al base alloys and the Ni-basesuperalloys currently in service.

The development of suitable ODS Fe3Al materials andprocesses shall endeavor to achieve high mechanicalstrength at temperature, as well as prolonged creep-life inservice. Post-deformation recrystallization or zoneannealing processes shall be examined as necessary toincrease the grain size and to modify the grain shape forthe anticipated use.

Keywords: Alloys

399. FATIGUE AND FRACTURE BEHAVIOR OF Cr-XALLOYS$75,000DOE Contacts: F. M. Glaser (301) 903-2784,



University of Tennessee Contact: P. K. Liaw (865) 974-6356

The objective of this research is to characterize thefatigue and fracture behavior of Cr2Nb-based alloys andother intermetallic materials at ambient and elevatedtemperatures in controlled environments. These studiesare expected to lead to mechanistic understanding of thefatigue and fracture behavior of these alloys. Fatiguetests are conducted for the purpose of evaluating crackinitiation and fatigue life of Cr2Nb-based alloys as well asother intermetallic alloys.

Keywords: Alloys

ULTRA-SUPERCRITICAL STEAM POWER PLANTRESEARCH

400. ULTRA-SUPERCRITICAL STEAM TURBINEMATERIALS$200,000DOE Contacts: F. M. Glaser (301) 903-2784,


Albany Research Center Contact: Richard P. Walters (541) 967-5873

This research will provide the base materials technologyneeded to design steam turbines capable of operating attemperatures and pressures typical of ultra-supercriticalsteam conditions. The tasks to be undertaken include:1) a detailed review of the current technology; 2) theidentification of the critical issues and major barriers inrelation to the target high pressure (HP), intermediatepressure (IP), and low pressure (LP) steam condition;

3) the identification of promising materials and a plan toevaluate and qualify materials for the critical components;and 4) the recommendation of materials constitutiveequations, damage evaluation criteria, and life-predictioncriteria that would be needed for a proof-of-conceptdesign and analysis.

Keywords: Materials, Power Plants, Turbines

401. MATERIALS FOR ULTRA-SUPERCRITICALSTEAM POWER PLANTS$0DOE Contacts: F. M. Glaser (301) 903-2784,



This research is part of eight tasks undertaken by aconsortium of utilities, boiler manufacturers, materialsproducers, the Electric Power Research Institute, theState of Ohio, and the U.S. Department of Energy whichare directed toward resolving the major materials issuesconfronting the ultra-supercritical coal power plant. Thesetasks include 1) conceptual design and economicanalysis, 2) mechanical properties of advanced alloys,3) steam-side oxidation evaluations, 4) fireside corrosionevaluations, 5) welding development, 6) fabricationdevelopment, 7) coating development, and 8) designmethodology. The achievement of the goals of thisprogram will produce the capability to construct andoperate a boiler to steam conditions of 760/C (1400/F)and 35 MPa (5000 psig).

Keywords: Materials, Power Plants

402. ULTRA-SUPERCRITICAL STEAM CYCLETURBINE MATERIALS $350,000DOE Contacts: F. M. Glaser (301) 903-2784,



This research will provide the base materials technologyneeded to design steam turbines capable of operating attemperatures and pressures typical of ultra-supercriticalsteam conditions. The tasks to be undertaken include:1) a detailed review of the current technology; 2) theidentification of the critical issues and major barriers inrelation to the target high pressure (HP), intermediatepressure (IP), and low pressure (LP) steam condition;3) the identification of promising materials and a plan toevaluate and qualify materials for the critical components;and 4) the recommendation of materials constitutiveequations, damage evaluation criteria, and life-prediction


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criteria that would be needed for a proof-of-conceptdesign and analysis.

Keywords: Materials, Power Plants, Turbines

VISION 21 SUPPORT ACTIVITIES

403. IMPROVED ODS ALLOY FOR HEATEXCHANGER TUBING$105,999DOE Contacts: F. M. Glaser, (301) 903-2784 and

R. B. Read (412) 386-5721Special Metals Contact: M.A. Harper

(304) 526-5057

Certain key components have been indentified asnecessary for the success of a Vision 21 power plant,one of which is a high temperature heat exchanger. Theproject is to develop/produce an oxide dispersionstrengthened (ODS) heat exchanger tube such that a fullscale heat exchanger can be manufactured, and the alloyMA956 has been chosen for the material in this study.The main limitations of current ODS tubing are their poorweldability and relatively poor circumferential creepstrength at elevated temperatures. Thus far, these twocharacteristics have restricted ODS materials to mostlynon-pressure containing applications. Currentconventional heat exchanger alloys have a maximumoperating temperature of approximately 732/C/1350/F.Also, the maximum practical limit for current wrought Ni-base superalloys would be 860/C/1580/F. This Vision 21project will use novel tube processing modifications todevelop ODS tubes with sufficient strength for long termuse at much higher temperatures (T>1093/C/2000/F). Inaddition, advanced welding techniques will be used todevelop a joining method which will produce adequatejoints on ODS materials. Thus the major tasks related tothis objective are: (a) increasing the circumferentialstrength of a MA956 tube, (b) joining of the MA956 tube,and (c) determining the high temperature corrosion limitsof the MA956 alloy in expected Vision 21 power plantenvironments.

Keywords: Oxide Dispersion Strengthened Alloys,Joining, Corrosion, Heat Exchanger,Vision 21

ADVANCED METALLURGICAL PROCESSESPROGRAM

The materials program at the Albany Research Center(ARC), formerly with the Bureau of Mines, incorporatesAdvanced Metallurgical Processes that provide essentiallife-cycle information for evaluation and development ofmaterials. The research at ARC directly contributes to FEobjectives by providing information on the performancecharacteristics of materials being specified for the currentgeneration of power systems, on the development ofcost-effective materials for inclusion in the nextgeneration of fossil fired power systems, and for solving

environmental emission problems related to fossil firedenergy systems. The program at ARC stresses fullparticipation with industry through partnerships andemphasizes cost sharing to the fullest extent possible.

The materials research in the Program focuses onextending component service lifetimes through theimprovement and protection of current materials, by thedesign of new materials, and by defining the serviceoperating conditions for new materials in order to ensuretheir safe and effective use. This process involvesdeveloping a better understanding of specific failuremodes for materials in severe operating environments,addressing factors which limit their current use in theseenvironments, and by designing new materials andmaterials processing procedures to overcome anticipatedusage challenges in severe operating environments, suchas those typically found in fossil energy generating plantsand in structures and supporting facilities associated withoil and gas production. Emphasis is placed onhigh-temperature erosion testing and modeling inenvironments anticipated for Vision 21 plants,development of casting technologies and new alloys toimprove wear resistance in those environments, ondevelopment of sulfidation/oxidation resistant materialswhich can also resist thermal cycling for pressurizedcirculating fluidized bed reactors, and on repair anddevelopment of refractory materials for coal gasifiers.DOE contact is Richard Walters, (541) 967-5873.


404. ADVANCED FOIL LAMINATION TECHNOLOGY$560,000DOE Contact: Richard P. Walters, (541) 967-5873 Albany Research Center Contact:

Arthur V. Petty, Jr. (541) 967-5878

ARC researchers have developed a materials fabricationapproach that utilizes dissimilar foils to produce a varietyof materials (e.g., layered composites, monolithic metallicand intermetallic alloys). The research has identifiedbonding parameters for laminating type 347-stainlesssteel foils. This technique has also been used to joindissimilar metals. The goal of this research is to useconventional deformation processing techniques (such asextrusion or rolling) to bond foils to substrates and toeach other.

Keywords: Aluminides, Coatings, Foil-LaminationProcess


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405. ADVANCED CASTING TECHNOLOGIES$400,000DOE Contact: Richard P. Walters (541) 967-5873Albany Research Center Contact: Paul C. Turner

(541) 967-5863

Most wear-resistant components are produced usingmetal casting technologies. ARC has developedexpertise in recent advanced casting technologies, whichmay be applied to production of components for fossilenergy plants. The goal of the research is to understandthe mechanisms of current component degradation andto produce new alloys via casting for increased servicelife and power plant operational efficiency.

Keywords: Alloys, Casting


406. ADVANCED REFRACTORIES FOR GASIFIERS$600,000DOE Contact: Richard P. Walters (541) 967-5873Albany Research Center Contact:

Arthur V. Petty, Jr. (541) 967-5878

The emphasis of this high temperature material researchhas been driven by both short-range industrial needs andlong-range issues in gasifiers. Program emphasis is on:1) identifying material failure mechanisms, 2) identifying/developing materials that will extend the lifetime ofprimary refractory liners in slagging gasifier systems,3) developing repair techniques to shorten systemdowntime caused by refractory maintenance, and4) developing improved thermocouples/temperature-monitoring techniques. A refractory material withimproved resistance to attach by molten coal slags insimulated gasifier environments has been developed.

Keywords: Refractories, Slagging Gasifier, Liners,Thermocouples

407. OXIDATION AND SULFIDATION RESISTANTMATERIALS$600,000DOE Contact: Richard P. Walters, (541) 967-5873Albany Research Center Contacts:

Arthur V. Petty, Jr. (541) 967-5878 and Cindy Do—an (541) 967-5803

The goal of this research is to develop modified austeniticstainless steels with performance characteristicsnecessary for process streams in advanced heatrecovery and hot gas cleanup systems employed withadvanced power generation systems (IGCC, PFBC andIGFC). The most difficult near term R&D challenges aredevelopment of hot gas particulate and sulfur cleanupsystems employed with these advanced powergeneration systems. Primary focus is on the development

of TiC-reinforced cast austenitic stainless steels with Aland Si additions for oxidation and sulfidation resistance.

Keywords: Alloys, Casting, Cast Austenitic StainlessSteel, Titanium Carbide

408. WEAR AND ABRASION OF MATERIALS FORFOSSIL ENERGY SYSTEMS$600,000DOE Contact: Richard P. Walters (541) 967-5873Albany Research Center Contact: Cindy Dogan

(541) 967-5803

Wear and erosion are significant materials-relatedproblems found in the operation of fossil energy plants.By understanding the general wear and erosionmechanisms that occur in coal preparation and plantoperation, materials and procedures can be developed toreduce the effects of these mechanisms. A betterunderstanding of micro-mechanisms of material removalis needed, as well as a basic understanding of themechanics of deformation during erosion. The projectinvestigates preparation of non-conventional materialsand their performance under simulated pulverized coalcombustion plant conditions. Improvements will result inhigher efficiency, less maintenance and fewercatastrophic failures in fossil energy plants. Anunderstanding of material behavior under conditions ofimpact by dry particles will be developed along the way,through understanding the contact mechanics of theimpact process and by investigating and characterizingthe damage inflicted on various materials by impact ofparticles.

Keywords: Abrasion, Erosion, Oxidation, Corrosion,Wear

409. MECHANISMS OF CORROSION UNDER ASHDEPOSITS$550,000DOE Contact: Richard P. Walters, (541) 967-5873Albany Research Center Contact: Cindy Dogan

(541) 967-5803

The focus of the project is understanding the effect of ashdeposits on the corrosion of metals and alloys, anddeveloping recommendations for improved alloys oroperating conditions to reduce the level of corrosion.Three power generation industries (coal combustion, coalgasification, and waste incineration) share the problem ofaccelerated corrosion of metallic components due to ashdeposition. While ash composition is different for each ofthese industries, all of the ash deposits tend to absorbimpurities from the gaseous atmosphere, keeping themnear the metal surface where the corrosion reactionoccurs.

Keywords: Corrosion, Molten Salts, Hot Corrosion


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410. NON-ISOTHERMAL CORROSION ANDOXIDATION$288,000DOE Contact: Richard P. Walters, (541) 967-5873Albany Research Center Contact: Cindy Dogan,

(541) 967-5803

Large temperature gradients and heat fluxes occur inturbines, heat exchangers, and walls of fossil energypower plants. The objective of this research is todetermine the effects of thermal gradients and heat fluxeson oxidation, sulfidation, and hot corrosion behavior ofmetals commonly used in high-temperature componentsof fossil energy power plants. A thermal cycling testfacility will examine non-isothermal oxidation and hotcorrosion.

Keywords: Oxidation, Corrosion, Thermal Gradient

Directory

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DIRECTORY

J. D. Achenbach Department of Civil EngineeringNorthwestern UniversityEvanston, IL 60201(847) 491-5527

L. F. AllardORNLP.O. Box 2008Bldg. 4515, MS 064Oak Ridge, TN 37831(865) 574-4981

Richard AndersonKroftt-Brakston International, Inc.5836 Sunrise AvenueClaendon Hills, IL 60514(708) 655-3207

P. AngeliniORNLP.O. Box 2008Bldg. 4515, MS 6065Oak Ridge, TN 37830-6065(865) 574-4565

T. W. ArrigoniU.S. Dept. of EnergyP.O. Box 10940Pittsburgh, PA 15236(412) 972-4450

J. S. ArzigianDivision 1815Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-2465

R. A. AssinkDivision 1811Sandia National LaboratoriesAbuquerque, NM 87185(505) 844-6372

D. G. Austin9493 Dutch Hollow RoadRixeyville, VA 22737(540) 937-7953

V. Saimasarma AvvaN. Carolina State Univ.Grahm Hall #8Greensboro, NC 27411(919) 379-7620

Walter C. BabcockBend Research, Inc.64550 Research RoadBend, OR 97701-8599(503) 382-4100

Samuel J. BarishER-32/GTNU.S. Dept. of Energy19901 Germantown RoadGermantown, MD 20874-1290(301) 903-3054

Lisa BarnettEE-2K/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-2212

Harold N. BarrHittman Mat. & Med. Components, Inc.9190 Red Branch RoadColumbia, MD 21045(301) 730-7800

Bulent BasolInternl. Solar Electric Tech., Inc.8635 Aviation BoulevardInglewood, CA 90301(310) 216-4427

J. L. BatesPacific Northwest LaboratoriesP.O. Box 999Richland, WA 99352(509) 375-2579

S. Bauer, Division G314Sandia National LaboratoryP.O. Box 5800Albuquerque, NM 87185(505) 846-9645

M. B. BeardsleyCaterpillar, Inc.100 N.E. Adams StreetPeoria, IL 61629(309) 578-8514

R. L. BeattyORNLP.O. Box 2008Bldg. 4508, MS 088Oak Ridge, TN 37831(865) 574-4536

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186

P. F. BecherORNLP.O. Box 2008Bldg. 4515, 068, Room 275Oak Ridge, TN 37831-6088(865) 574-5157

David J. BeecyFE-72/FORSU.S. Dept. of EnergyWashington, DC 20585(301) 903-2787

Mohamad M. BehraveshNuclear Plant Corrosion ControlElectric Power Research Institute3412 Hillview AvenuePalo Alto, CA 94303(650) 855-2388

William L. BellTDA Research, Inc.12345 West 52nd AvenueWheat Ridge, CO 80033(303) 940-2301

John BennerSolar Electric Conversion Div.NREL1617 Cole Blvd.Golden, CO 80401(303) 384-6496

Clifton G. BergeronUniversity of Illinois105 South Goodwin Avenue204 Ceramics BuildingUrbana, IL 61801(217) 333-1770

Sam BermanBldg. 90, Rm. 3111Lawerence Berkeley LaboratoryUniversity of CaliforniaBerkeley, CA 94720(510) 486-5682

Marita L. BerndtDept. of Energy Sciences & TechnologyBrookhaven National Laboratory, Bldg. 526Upton, NY 11973(631) 344-3060

Theodore M. BesmannMetals and Ceramics DivisionOak Ridge National LaboratoryP.O. Box 2008Oak Ridge, TN 37831(865) 574-6852

Fritz BienSpectral Sciences, Inc.99 South Bedford Street, #7Burlington, MA 01803-5169(617) 273-4770

J. BockrisTexas A&M UniversityCollege Station, TX 77843-3255(713) 845-5335

Robert BoettnerEE-112/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 252-9136

W. D. BondOak Ridge National LaboratoryP.O. Box 2008Bldg. 7920, 384, Room 0014Oak Ridge, TN 37831-6088(865) 574-7071

J. A. M. BouletUniversity of Tennessee310 Perkins HallKnoxville, TN 37996(865) 974-8376

D. J. BradleyPacific Northwest National LaboratoryRichland, WA 99352(509) 375-2587

R. A. BradleyORNLP.O. Box 2008 Bldg. 4515Oak Ridge, TN 37831-6067(865) 574-6094

Joyce M. BrienResearch International, Inc.18706-142nd Avenue, NEWoodinville, WA 98072(206) 486-7831

C. R. BrinkmanORNLP.O. Box 2008Bldg. 4500-S, MS 154Oak Ridge, TN 37831(865) 574-5106

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187

Leslie BrombergPlasma Fusin CenterMA Institute of Tech.Cambridge, MA 02139(617) 253-6919

J. A. BrooksDivision 8312Sandia National LaboratoriesLivermore, CA 94550(925) 422-2051

Alexander BrownChesapeake Composites Corporation239 Old Churchman's RoadNew Castle, DE 19720(302) 324-9110

Ian G. BrownLawrence Berkeley LaboratoryBerkeley, CA 94720(510) 486-4147

S. T. BuljanGTE Laboratories, Inc.40 Sylvan RoadWaltham, MA 02254(617) 890-8460

Kenneth R. ButcherSelee Corporation700 Shepherd StreetHendersonville, NC 28792(704) 697-2411

Oral BuyukozturkMIT77 Massachussetts AvenueCambridge, MA 02139(617) 253-7186

Elton CairnsLawrence Berkeley LaboratoryUniversity of CaliforniaBerkeley, CA 94720(510) 486-5028

Juan CarbajoORNLP.O. Box YOak Ridge, TN 37831(865) 574-3784

R. W. Carling, Div. 8313Sandia National LaboratoriesLivermore, CA 94550(925) 422-2206

P. T. CarlsonOak Ridge National LaboratoryP.O. Box 2008Oak Ridge, TN 37831(865) 574-5135

D. W. CarrollLANLLos Alamos, NM 87545(505) 667-2145

Gloria M. CatonORNL1060 Commerce ParkMS 6480Oak Ridge, TN 37830(865) 574-7759

Ken ChaceyEM-34/GTNU.S. Dept. of EnergyWashington, DC 20545(301) 903-7186

A. T. ChapmanGeorgia Institute of TechnologyGeorgia Tech Research InstituteAtlanta, GA 30332-0420(404) 894-4815

Yok ChenSC-131/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-3428

Lalit ChhabildasOrg. 1433 Mail Stop 0821P.O. Box 5800Sandia National LaboratoryAlbuquerque, NM 87185(505) 844-4147

Richard ChristensenLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 422-7136

L. ChristophorouORNLP.O. Box 2008Bldg. 4500S, 122, Rm. H156Oak Ridge, TN 37831(865) 574-6199

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188

Russel J. ChurchillAmerican Research Corp. of Va.642 First StreetP.O. Box 3406Radford, VA 24143-3406(703) 731-0836

M. J. CieslakMS 0887Sandia National LaboratoriesP.O. Box 5800Albuquerque, NM 87185-0887(505) 846-7500

D. E. ClarkMaterials Technology DivIdaho National Eng. LaboratoryIdaho Falls, ID 83415(208) 526-0746

S. K. ClarkDept. of Mech. Eng. & App. Mech.University of MichiganAnn Arbor, MI 48109(313) 764-4256

David ClarkeUniv. of CaliforniaMaterials DepartmentEngineering IIISanta Barbara, CA 93106(805) 893-8275

R. L. CloughSandia National LaboratoriesAlbuquerque, NM 87185(505) 844-3492

Joe K. Cochran, Jr.School of Ceramic Eng.Georgia Inst. of TechnologyAtlanta, GA 30332(404) 894-2851

Robert CookLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 422-6993

Alastair N. CormackNYS College of CeramicsAlfred UniversityAlfred, NY 14802(607) 871-2180

J. E. CostaDivision 8314Sandia National LaboratoriesLivermore, CA 94550(925) 422-2352

James V. CrivelloDepartment of ChemistryRensselaer Polytechnic InstituteTroy, NY 12180-3590(518) 276-6825

Randy CurleeORNLP.O. Box 2008Oak Ridge, TN 37831(865) 576-4864

David I. CurtisNR-1 Bldg. 104U.S. Dept of EnergyWashington, DC 20585(202) 781-6141

G. J. D'AlessioDP-242/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-6688

S. J. DapkunasNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 975-6119

John DavisMcDonnell Douglas Astro. Co.Fusion Energy ProgramP.O. Box 516, Bldg 278St. Louis, MO 63166(314) 234-4826

Robert F. DavisDept. of Materials Eng.North Carolina State University232 Riddick Lab, Box 7907Raleigh, NC 27695(919) 737-3272

Victor DerER-531/FORSU.S. Dept. of EnergyWashington, DC 20585(301) 903-5736

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189

R. DiegleDivision 1841Sandia National LabsAlbuquerque, NM 87185(505) 846-3450

R. DiercksMat. Science & Tech. Div.Argonne National Labs9700 South Cass AveArgonne, Illinois 60439(630) 972-5032

Larry A. DomineyCovalent Associates, Inc.10 State StreetWoburn, MA 01801(617) 938-1140

Elaine DrewSupercon, Inc.830 Boston TurnpikeShrewsbury, MA 01545(508) 842-0174

C. DuffyLANL P.O. Box 1663Los Alamos, NM 87545(505) 843-5154

E. M. DunnGTE Laboratories, Inc.40 Sylvan RoadWaltham, MA 02254(617) 466-2312

Sunil DuttaNASA Lewis Research Center21000 Brookpark Road, MS 49-3Cleveland, OH 44135(216) 433-3282

Christopher A. EbelNorton CompanyGoddard RoadNorthboro, MA 01532-1545(617) 393-5950

James J. EberhardtEE-2G/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-9837

G. R. EdwardsColorado School of MinesGolden, CO 80401(303) 273-3773

Paul EggerstedtInd. Filter & Pump Man. Co.5900 Ogden AvenueCicero, IL 60650(708) 656-7800

W. A. EllingsonArgonne National LaboratoriesMat. Science Div., Bldg. 2129700 South CassArgonne, Illinois 60439(630) 252-5068

Gerald EntineRadiation Monitoring Devices, Inc.44 Hunt StreetWatertown, MA 02172(617) 926-1167

Mike EpsteinBattelle-Columbus Labs505 King AvenueColumbus, OH 43201(614) 424-6424

John FairbanksEE-2G/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-8066

P. D. FairchildORNLP.O. Box YBldg. 9102-2, 001, Room 0210Oak Ridge, TN 37831(865) 574-2009

D. A. FarkasVirginia Polytechnic Institute and UniversityMat. Sci. and Eng.201 A Holden HallBlacksburg, VA 24061(540) 231-4742

Cynthia K. FarrarMontec Associates, Inc.P.O. Box 4182Butte, MT 59702(406) 494-2596

W. FeduskaWestinghouse Electric Corp.R&D Center1310 Beulah RoadPittsburgh, PA 15235(412) 256-1951

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190

Robert S. FeigelsonCenter for Materials ResearchStanford UniversityStanford, CA 94305(650) 723-4007

Mattison K. FerberORNLP.O. Box 2008Building 4515Oak Ridge, TN 37831-6064(865) 576-0818

Nicholas FioreCarpenter Technology Corp.101 West Bern StreetP.O. Box 14662Reading, PA 19612(215) 371-2556

Ronald J. FiskumEE-422/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-9130

D. M. FollstaedtDivision 1110Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-2102

Christopher A. FosterCryogenic Applications F, Inc.450 Bacon Springs LaneClinton, TN 37716(865) 435-5433

Mark FreiEM-34/FORSU.S. Dept. of EnergyWashington, DC 20585(301) 903-7201

Ehr-Ping Huang FuThermal ScienceEE-2F/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-1493

P. W. FuerschbachDivision 1833Sandia National LaboratoriesAlbuquerque, NM 87185(505) 846-2464

E. R. FullerNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 921-2942

F. D. GacLANL/MS G771Los Alamos, NM 87545(505) 667-5126

G. F. GallegosLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 422-7002

F. P. Gerstle, Jr.Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-4304

C. P. GertzYucca Mountain Project Mgr.U.S. Dept. of EnergyP.O. Box 98518Las Vegas, NV 89193(702) 794-7920

Larry GestautEltech Systems Corp.Painsville, OH 44077(216) 357-4041

R. GlassLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 423-7140

Leon GlicksmanMIT77 Massachussetts AvenueCambridge, MA 02139(617) 253-2233

Martin GlicksmanRensselear Polytechnic Inst.Materials Research Ctr. - 1048th StreetTroy, NY 12180-3690(518) 276-6721

Directory

191

Robert L. GoldsmithCeraMem Corporation12 Clematis AvenueWaltham, MA 02154(617) 899-0467

B. GoodmanNREL1617 Cole BlvdGolden, CO 80401(303) 231-1005

S. H. GoodsDivison 8314Sandia National LaboratoriesLivermore, CA 94550(925) 422-3274

R. J. GottschallER-13/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-3427

Anton C. GreenwaldSpire CorporationOne Patriots ParkBedford, MA 01730-2396(617) 275-6000

N. GrossmanNE-42/FORSU.S. Dept. of EnergyWashington, DC 20585(301) 903-3745

Dieter M. GruenMaterials Science DivisionArgonne National Laboratory9700 South Cass AvenueArgonne, IL 60439(630) 252-3513

Adi R. GuzdarFoster-Miller, Inc.350 Second AvenueWaltham, MA 02154(617) 890-3200

John P. GyeknyesiNASA Lewis Research Center2100 Brookpark Road, MS 49-7Cleveland, OH 44135(216) 433-3210

J. S. HaggartyMIT77 Massachussetts AvenueCambridge, MA 02139(617) 253-2129

Phil HaleyAllison Turbine OperationsP.O. Box 420Indianapolis, IN 46206-0420(317) 230-2272

David G. HamblenAdvanced Fuel Research, Inc.87 Church StreetP.O. Box 380379East Hartford, CT 06138-0379(203) 528-9806

Edward P. HamiltonAmerican Superconductor Corp.2 Technology DriveWestboro, MA 01581(508) 836-4200

Debbie HaughtEE-2D/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-2211

Jeff HayChem.-Mat. Science Div.Los Alamos National LabLos Alamos, NM 87545(505) 843-2097

Norman L. HechtUniversity of Dayton 300 College Park, KL165Dayton, OH 45469-0001(513) 229-4343

Kamithi HemachalamIntermagnetics General Corp.1875 Thomaston AvenueWaterbury, CT 06704(203) 753-5215

Mary T. HendricksAlabama Cryogenic Engineering, Inc.P.O. Box 2470Huntsville, AL 35804(205) 536-8629

Directory

192

Carolyn J. HenkensAndcare, Inc.2810 Meridian ParkwaySuite 152Durham, NC 27713(919) 544-8220

Carl HenningLawrence Livermore Nat. LabP.O. Box 5511Livermore, CA 94550(925) 532-0235

G. Duncan HitchensLynntech, Inc.7610 Eastmark DriveSuite 105College Station, TX 77840(409) 693-0017

Kai-Ming HoInst. for Physical Research and TechnologyAmes LaboratoryAmes, IA 50011(515) 294-1960

J. M. HobdayMETCP.O. Box 880Morgantown, WV 26505(304) 291-4347

D. M. HoffmanLawrence Livermore Nat. LabUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(510) 422-7759

E. E. HoffmanU.S. Dept. of EnergyP.O. Box 2001Oak Ridge, TN 37831-8600(865) 576-0735

Linda L. HortonOak Ridge National LaboratoryBox 2008, Bldg. 4500-SOak Ridge, TN 37831-6118(865) 574-5081

E. Philip HorwitzChemistry DivisionArgonne National Laboratory9700 South Cass AvenueArgonne, IL 60439(630) 252-3653

Stephen M. HsuCenter for Materials ScienceNational Measurements LabNISTGaithersburg, MD 20899(301) 975-6119

Donald R. HuffmanDept. of PhysicsUniversity of ArizonaTucson, AZ 85721(520) 621-4804

Arlon HuntLawrence Berkeley LaboratoryUniversity of CaliforniaBerkeley, CA 94720(925) 486-5370

George F. HurleyChemistry-Materials Sci. Div.Los Alamos National LaboratoryLos Alamos, NM 87545(505) 667-9498

Mallika D. IlindraSumi Tech, Inc.3006 McLean CourtBlacksburg, VA 24060(540) 552-8334

D. David IngramUniversal Energy Systems, Inc.4401 Dayton-Xenia RoadDayton, OH 45432(513) 426-6900

L. K. IvesNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 921-2843

David A. JacksonEnergy Photovoltaics, Inc.276 Bakers Basin RoadLawrenceville, NJ 08648(609) 587-3000

Jonah JacobScience Research Lab, Inc.15 Ward StreetSomerville, MA 02143(617) 547-1122

Directory

193

N. S. JacobsonNASA Lewis Research Center21000 Brookpark RoadCleveland, OH 44135(216) 433-5498

Radha JalanElectroChem, Inc.400 West Cummings ParkWoburn, MA 01801(617) 932-3383

Mark A. JanneyORNLP.O. Box 2008Bldg. 4515, 069, Room 228Oak Ridge, TN 37831-6088(865) 574-4281

J. E. JensenCVI Inc.P.O. Box 2138Columbus, OH 43216(614) 876-7381

Carl E. JohnsonChemical Technology DivisionArgonne National Laboratory9700 Cass Ave, Bldg. 205Argonne, IL 60439(630) 252-7609

Curtis A. JohnsonGE Research LaboratoryP.O. Box 8Bldg. 31 #3C7Schenectady, NY 12301(518) 387-6421

D. Ray JohnsonORNL, Metals & Ceramics Div.P.O. Box 2008Bldg. 4515, 066, Room 206Oak Ridge, TN 37831-6088(865) 576-6832

Robert JonesLos Alamos National Lab.P.O. Box 1663, M/S J577Los Alamos, NM 87545(505) 667-6441

Robert A. JonesDP-28/GTNU.S. Dept. of EnergyWashington, DC 20545(301) 903-4236

Landis KannbergPacific Northwest LabBattlelle Blvd.P.O. Box 999Richland, WA 99352(509) 375-3919

Michael E. KarpukTDA Research, Inc.12345 West 52nd AvenueWheat Ridge, CO 80033(303) 940-2301

M. E. KassnerOregon State UniversityDept. Of Mechanical EngineeringRogers 204Corvallis, OR 97331-5001(541) 737-7023

Carlos KatzCable Technology LabP.O. Box 707New Brunswick, NJ 08903(201) 846-3220

Joel KatzLANLP.O. Box 1663/MS G771Los Alamos, NM 87545(505) 665-1424

Robert N. KatzWorcester Polytechnical Inst.Dept. of Mechanical Eng.100 Institute StreetWorcester, MA 01609(508) 831-5336

Larry KazmerskiSolar Electric Conv. Div.NREL1617 Cole Blvd.Golden, CO 80401(303) 384-6600

M. R. KeenanDivision 1813Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-6631

J. R. KeiserORNLP.O. Box 2008Bldg. 4500-S, 156, Room 0734Oak Ridge, TN 37830(865) 574-4453

Directory

194

Rudolf KellerEMEC Consultants4221 Roundtop RoadExport, PA 15632(412) 325-3260

Han KimGTE Labs40 Sylvan RoadWaltham, MA 02254(617) 466-2742

Christopher N. KingPlanar Systems, Inc.1400 Northwest Compton DriveBeaverton, OR 97006(503) 690-1100

Richard KingEE-2A/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-1693

J. H. KinneyLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 422-6669

G. S. KinoEdward Ginzton LaboratoryStanford UniversityStanford, CA 94305(925) 497-0205

Paul KlemmensUniversity of ConnecticutBox U-46Storrs, CT 06268(860) 486-3134

S. J. KlimaNASA Lewis Research CenterMS 106-121000 Brookpark RoadCleveland, OH 44135(216) 433-6020

J. A. KnappDivision 1110Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-2305

G. A. KnorovskyDivision 1833Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-1109

Timothy R. KnowlesEnergy Science Labs, Inc.6888 Nancy Ridge DriveSan Diego, CA 92121-2232(619) 552-2034

Victor R. KochCovalent Associates, Inc.10 State StreetWoburn, MA 01801(617) 938-1140

Dale KoellingSC-13/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-2187

K. G. KreiderNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 975-2619

David KurtzAdvanced Technology Materials, Inc.7 Commerce DriveDanbury, CT 06810(203) 794-1100

S. R. KurtzDivision 1811Sandia National LaboratoriesAlbuquerque, NM 87185 (505) 844-5436

Richard J. LagowDepartment of ChemistryThe Univ. of Texas at AustinAustin, TX 78712(512) 471-1032

James LankfordSouthwest Research Inst.6220 Culebra RoadP.O. Drawer 28510San Antonio, TX 78284(512) 684-5111

Directory

195

R. LaSalaEE-2C/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-4198

W. N. LawlessCeramPhysics, Inc.921 Eastwind Drive, Suite 110Westerville, OH 43081(614) 882-2231

S. R. LeeU.S. Dept. of EnergyP.O. Box 10940Pittsburgh, PA 15236(412) 675-6137

Franklin D. LemkeyUnited Tech. Research Ctr.Silver LaneEast Hartford, CT 06108(860) 727-7318

Douglas LemonPacific Northwest LabsP.O. Box 999Richland, WA 99352(509) 375-2306

S. R. LevineNASA Lewis Research Center21000 Brookpart RoadCleveland, OH 44135(216) 433-3276

C. T. Liu, Mtl. Ceram. Div.ORNLP.O. Box 2008Bldg. 4500-S, 115, Rm. S280Oak Ridge, TN 37831(865) 574-5516

K. C. LiuORNLP.O. Box 2008Bldg. 4500-S, MS 155Oak Ridge, TN 37831(865) 574-5116

Richard W. LongsderffThermacore, Inc.780 Eden RoadLancaster, PA 17601(717) 569-6551

R. O. LoutfyMat. & Electro. Research Corp.7960 South Kolb RoadTucson, AZ 85706(602) 574-1980

T. C. LoweDivison 8316Sandia National LaboratoriesLivermore, CA 94550(925) 422-3187

C. D. Lundin307 Dougherty Eng. Bldg.University of TennesseeKnoxville, TN 37996(865) 974-5310

MAJ Ross E. LushboughDP-225.2/FORSU.S. Dept. of EnergyWashington, DC 20585(301) 903-3912

Richard MahLos Alamos National LabP.O. Box 1663Los Alamos, NM 87545(505) 607-3238

Mokhtas S. MakladEOTEC Corporation420 Frontage RoadWest Haven, CT 06516(203) 934-7961

Frederick M. MakoFM Technologies4431-H Brookfield Corporate DriveChantilly, VA 20151(703) 961-1051

A. C. MakridesEIC Laboratories, Inc.111 Downey StreetNorwood, MA 02062(617) 769-9450

Mark K. MalmrosMKM Research/OhmicronP.O. Box IWashington Crossing, PA 18977(609) 737-9050

Matthew MarroccoMaxdem, Inc.140 East Arrow HighwaySan Dimas, CA 91773(909) 394-0644

Directory

196

R. G. MartinAnalysis Consultants21831 Zuni DriveEl Toro, CA 92630(714) 380-1204

H. MaruEnergy Research Corporation3 Great Pasture RoadDanbury, CT 06810(203) 792-1460

K. MasubuchiLab for Manuf. and Prod.MITCambridge, MA 02139(617) 255-6820

Ronald D. MatthewsDept. of Mechanical EngineeringThe University of Texas at AustinAustin, TX 78712(512) 471-3108

Douglas McAllisterBIODE, Inc.2 Oakwood RoadCape Elizabeth, ME 04107(207) 883-1492

D. McCrightLLNLUniversity of CaliforniaLivermore, CA 94550(213) 423-7051

Patrick N. McDonnellSpire CorporationOne Patriots ParkBedford, MA 01730-2396(617) 275-6000

David L. McElroyORNLP.O. Box 2008Bldg. 4508, 092, Rm. 239Oak Ridge, TN 37831-6088(865) 574-5976

A. J. McEvilyMetallurgy Dept., U-136University of ConnecticutStoras, CT 06268(860) 486-2941

T. D. McGeeMat. Science & Engineering110 Engineering AnnexIowa State UniversityAmes, IA 50011(515) 294-9619

Carl McHargueUniversity of TennesseeMaterials & Eng. Dept.434 Doughtery Eng. Bldg.Knoxville, TN 37996-2200(865) 974-8013

Arthur S. MehnerNE-53/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-4474

G. H. Meier848 Benevum HallUniversity of PittsburghPittsburgh, PA 15261(412) 624-5316

A. MeyerInternational Fuel CellsP.O. Box 739195 Governors Hwy.South Windsor, CT 06074(203) 727-2214

JoAnn MillikenEE-2H/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-2480

B. E. MillsSandia National LaboratoriesLivermore, CA 94550(925) 422-3230

Andrew MorrisonM/S 238-343Flat Plate Solar Array ProjectJet Propulsion LaboratoryPasadena, CA 91109(213) 354-7200

Craig MortensonBPA/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-5656

Directory

197

J. MoteffUniversity of CincinnatiDepartment of Material ScienceMetallurgical Engineering498 Rhodes HallCincinnati, OH 45221-0012(513) 475-3096

Leszek R. MotowidloIGC Advanced Superconductors1875 Thomaston AvenueWaterbury, CT 06704(203) 753-5215

Arnulf MuanPennsylvania State UniversityEMS Experiment Station415 Walker Bldg.University Park, PA 16802(814) 865-7659

L. Marty MurphyNREL1617 Cole BlvdGolden, CO 80401(303) 231-1050

J. NarayanMaterials Science & Eng.North Carolina State Univ.Box 7916Raleigh, NC 27695-7916(919) 515-7874

Michael NastasiLos Alamos National LabLos Alamos, NM 87545(505) 667-7007

K. NatesanArgonne National Lab.Materials Science Division9700 South CassArgonne, IL 60439(630) 252-5103

M. NaylorCummins Engine Co., Inc.Box 3005Mail Code 50183Columbus, IN 47202-3005(812) 377-5000

M. C. NicholsSandia National LaboratoriesLivermore, CA 94550(925) 422-2906

P. J. NigreyDivision 1150Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-8985

D. A. NissenSandia National LaboratoriesLivermore, CA 94550(925) 422-2767

T. A. NolanORNLP.O. Box 2008Bldg. 4515, MS 064Oak Ridge, TN 37831(865) 574-0811

Paul C. NordineContainerless Research, Inc.910 University PlaceEvanston, IL 60201-3149(708) 467-2678

P. C. OdegardDivison 8216Sandia National LaboratoriesLivermore, CA 94550(925) 422-2789

G. R. OdetteDept. of Chem. & Nuclear Eng.University of CaliforniaSanta Barbara, CA 93106(805) 961-3525

Thomas OhlemillerCenter for Bldg. TechnologyNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 921-3771

Ben OliverMaterials Science & Eng.421 Dougherty HallKnoxville, TN 37996(865) 974-5326

G. C. OsbournDivision 1130Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-8850

Roland OttoLawrence Berkeley Lab.Bldg 73, 106ABerkeley, CA 94720(510) 486-5289

Directory

198

G. M. OzeryanskyIGC Superconductors, Inc.1875 Thomaston AvenueWaterbury, CT 06704(203) 753-5215

Richard H. PantellElectrical Engineering Dept.Stanford UniversityStanford, CA 94305(650) 723-2564

E. R. Parker456 HearstUniv. of Ca., BerkeleyBerkeley, CA 24720(510) 642-0863

Bill ParksEE-2D/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-2093

D. O. PattenNorton CompanyHigh Performance CeramicsGoddard RoadNorthboro, MA 01532(617) 393-5963

Ahmad PesaranNREL1617 Cole Blvd.Golden, CO 80401(303) 231-7636

John PetrovicChemistry-Mat. Science Div.Los Alamos National LaboratoryLos Alamos, NM 87545(505) 667-5452

S. T. PicrauxDivision 1110Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-7681

R. D. PierceArgonne National LaboratoriesChemical Tech DivisionBldg. 205, Room W-125Argonne, IL 60439(630) 972-4450

Melvin A. PiestrupAdelphi Technology13800 Skyline Blvd.Woodside, CA 94062(925) 851-0633

Joseph PrahlCase Western Reserve Univ.Cleveland, OH 44106(216) 368-2000

Mark A. PrelasNuclear Engineering ProgramUniversity of MissouriColumbia, MO 65211(314) 882-3550

Peter PronkoUniversal Energy Systems4401 Dayton-Xenia RoadDayton, OH 45432(513) 426-6900

Herschel RabitzDept. of ChemistryPrinceton UniversityPrinceton, NJ 08544-1009(609) 258-3917

Robert RappDept. of Metal. Eng.Ohio State UniversityColumbus, OH 43210(614) 422-2491

Bhakta B. Rath, Assoc. Dir. Res.Naval Research LaboratoryMat. Science & Component Tech.Building 43, Room 212 - Code 6000Washington, DC 20375-5000(202) 767-3566

Rod RayBend Research, Inc.64550 Research RoadBend, OR 97701-8599(503) 382-4100

Brian RennexNatl. Institute of Standards and TechnologyCenter of Bldg. TechnologyGaithersburg, MD 20899(301) 921-3195

S. RichlenEE-2F/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-2078

Directory

199

R. O. Ritchie456 HearstUniversity of Cal., BerkeleyBerkeley, CA 24720(510) 642-0863

R. B. RobertoORNLSolid State DivisionP.O. Box 2008Oak Ridge, TN 37831-6030(865) 574-6151

D. I. RobertsGA TechnologiesP.O. Box 81608San Diego, CA 92138(619) 455-2560

S. L. RobinsonDivision 8314Sandia National LaboratoriesLivermore, CA 94550(925) 422-2209

Timothy L. RoseEIC Laboratories, Inc.111 Downing StreetNorwood, MA 02062(617) 764-9450

John H. RosenfeldThermacore, Inc.780 Eden RoadLancaster, PA 17601(717) 569-6551

P. N. RossMat. & Metal. Research Div.Lawrence Berkeley LabsUniversity of BerkeleyBerkeley, CA 94720(510) 486-4000

Giulio A. RossiNorton CompanyGoddard RoadNorthboro, MA 01532-1545(617) 393-5829

Walter RossiterCenter for Bldg. TechnologyNational Institute of Standards and TechnologyGaithersburg, MD 20899(301) 921-3109

M. RubinLawrence Berkeley LaboratoryUniversity of CaliforniaBerkeley, CA 94720(510) 486-7124

E. RussellLLNLUniversity of CaliforniaLivermore, CA 94550(925) 423-6398

C. O. Ruud159 MRLUniversity Park, PA 16802(814) 863-2843

John RyanEE-2J/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-8823

Djordjiji R. SainNuclear Con. Services, Inc.P.O. Box 29151Columbus, OH 43229(614) 846-5710

R. J. SalzbrennerDivision 1832Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-5041

Stuart SamuelsonDeltronic Crystal Industries, Inc.60 Harding AvenueDover, NJ 07801(201) 361-2222

J. SankarDept of Mechanical EngineeringNorth Carolina A&T UniversityGreensboro, NC 27411(919) 379-7620

Mike L. SantellaORNLP.O. Box 2008Oak Ridge, TN 37831-6088(865) 574-4805

Srinivasan SarangapaniICET, Inc.916 Pleasant StreetUnit 12Norwood, MA 02062(617) 679-6064

Directory

200

V. K. SarinGTE40 Sylvan RoadWaltham, MA 02254(617) 890-8460

Suri A. SastriSurmet Corporation33 B StreetBurlington, MA 01803(617) 272-3250

Jerome J. SchmidtJet Process Corporation25 Science ParkNew Haven, CT 06511(203) 786-5130

Erland M. Schulson33 Haskins RoadHanover, NH 03755(603) 646-2888

James SchwarzDept. Chem. Eng/Mat ScienceSyracuse University320 Hinds Hall Syracuse, NY 13244(315) 423-4575

James L. ScottMetals and Ceramics Div.ORNLP.O. Box 2008, Bldg. 4508Oak Ridge, TN 37831-6091(865) 624-4834

Timothy C. ScottChemical Technology DivisionOak Ridge National LaboratoryP.O. Box 2008Oak Ridge, TN 37831(865) 574-5962

R. E. SetchellDivision 1130Sandia National LabsAlbuquerque, NM 87185(505) 844-5459

Suzanne C. SheaPraxis Engineers, Inc.852 North Hillview DriveMilpitas, CA 95035(408) 945-4282

D. E. ShelorRW-3/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-9433

V. K. SikkaORNLP.O. Box 2008Bldg. 4508, 083, Rm. 129Oak Ridge, TN 37831(865) 574-5112

Richard SilberglittRAND1200 South Hayes StreetArlington, VA 22202(703) 413-1100 x5441

T. B. SimpsonFE-34/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-3913

J. P. SinghArgonne National Labs9700 South CassArgonne, IL 60439(630) 252-5123

Maurice J. SinnottChemical and Metall. Eng.University of MichiganH Dow BuildingAnn Arbor, MI 48109-2136(313) 764-4314

Piran SioshamsiSpire CorporationPatriots ParkBedford, MA 02173(617) 275-6000

Kurt D. SissonEE-222/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-6750

Jerry SmithSC-132/GTNU.S. Dept. of EnergyWashington, DC 20545(301) 903-3426

Directory

201

M. F. SmithDivision 1834Sandia National LaboratoriesAlbuquerque, NM 87185(505) 846-4270

Peter L. SmithNewton Optical Technologies167 Valentine StreetNewton, MA 02165(617) 495-4984

J. E. SmugereskyDivision 8312Sandia National LaboratoriesLivermore, CA 94550(925) 422-2910

Mike SoboroffIMF ProgramEE-2F/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-4936

N. R. SorensenDivision 1841Sandia National LaboratoriesAlbuquerque, NM 87185(505) 844-1097

Charles A. SorrellEE-2F/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-1514

R. F. SperleinU.S. Dept. of EnergyP.O. Box 10940Pittsburgh, PA 15236(412) 972-5985

J. R. SpringarnDivision 8312, SNLLivermore, CA 94550(925) 422-3307

Mark B. SpitzerSpire CorporationPatriots ParkBedford, MA 01730(617) 275-6000

T. L. StarrGeorgia Tech Res. Inst.Georgia Inst. of TechnologyAtlanta, GA 30332(404) 894-3678

Wayne S. SteffierHyper-Therm, Inc.18411 Gothard StreetUnits B & CHuntington Beach, CA 92648(714) 375-4085

Helmut F. SternArcanum CorporationP.O. Box 1482Ann Arbor, MI 48106(313) 665-4421

George StickfordBattelle-Columbus Labs505 King AvenueColumbus, OH 43201(614) 424-4810

Thomas J. StinerAstroPower, Inc.Solar ParkNewark, DE 19716(302) 366-0400

D. P. StintonORNLP.O. Box 2008Bldg. 4515, 063, Rm. 111Oak Ridge, TN 37831(865) 574-4556

Norman StoloffMaterials Engineering Dept.Rensselaer Polytechnic Inst.Troy, NY 12181(518) 266-6436

Paul D. StoneThe Dow Chemical Company1776 Eye Street, NW, #575Washington, DC 20006

J. E. StonekingDept. of Eng. Science & Mech.310 Perkins HallKnoxville, TN 37996(865) 974-2171

David SutterER-224/GTNU.S. Dept. of EnergyWashington, DC 20585(301) 903-5228

Directory

202

Richard SwansonSunPower Corporation435 Indio WaySunnyvale, CA 94086(408) 991-0900

R. W. SwindemanORNLP.O. Box 2008Bldg. 4500-S, 155, Rm. 0040Oak Ridge, TN 37831(865) 574-5108

W. TabakoffDept. of Aerospace Eng.M/L 70University of CincinnatiCincinnati, OH 45221(513) 475-2849

C. A. ThomasU.S. Dept. of EnergyP.O. Box 10940Pittsburgh, PA 15236(412) 972-5731

Iran L. ThomasER-10/GTNU.S. Dept. of EnergyWashington, DC 20545(301) 903-3426

D. O. ThompsonAmes LaboratoryIowa State UniversityAmes, IA 50011(515) 294-5320

T. Y. TienMat. and Metal. Eng.University of MichiganAnn Arbor, MI 48109(813) 764-9449

T. N. TiegsORNLBldg. 4515, 069, Rm. 230P.O. Box 2008Oak Ridge, TN 37831-6088(865) 574-5173

Jyh-Ming TingApplied Sciences, Inc.141 West Xenia AvenueP.O. Box 579Cedarville, OH 45314(513) 766-2020

R. H. TitranNASA Lewis Research Center21000 Brookpark Road, MS 49-1Cleveland, OH 44135(216) 433-3198

Zygmunt TomczukChemical Technology DivisionArgonne National Laboratory9700 South Cass AvenueArgonne, IL 60439(708) 252-7294

Micha TomkiewiczPhysics DepartmentBrooklyn College of City University of New YorkBrooklyn, NY 11210(718) 951-5357

John J. TomlinsonORNLBldg. 9204-1, MS 8045P.O. Box 2009Oak Ridge, TN 37831-8045(865) 574-0768

Carl R. Vander LindenVander Linden & AssociatesAIC Materials Program5 Brassie WayLittleton, CO 80123(303) 794-8309

Richard D. VarjianDow Chemical Company, Inc.Central Research - Catalysis1776 BuildingMidland, MI 49675(517) 636-6557

Matesh VarmaSC-13/GTNU.S. Dept. of Energy19901 Germantown RoadGermantown, MD 20874-1290(301) 903-3209

Krishna VedulaDept. of Metal. & Mat. ScienceCase Western Reserve University10900 Euclid AvenueCleveland, OH 44115(216) 368-4211

Robert W. VukusichUES, Inc.4401 Dayton-Xenia RoadDayton, OH 45432-1894(513) 426-6900

Directory

203

J. B. WalterMaterials Technology Div.Idaho National Eng. LabIdaho Falls, ID 83415(208) 526-2627

John WalterIntraSpec, Inc.P.O. Box 4579Oak Ridge, TN 37831(865) 483-1859

William K. WarburtonX-ray Instrumentation Associates1300 Mills StreetMenlo Park, CA 94025-3210(925) 903-9980

Craig N. WardUltramet 12173 Montague StreetPacoima, CA 91331(818) 899-0236

Gary S. WasDept. of Nuclear Eng.University of MichiganAnn Arbor, MI 48109(313) 763-4675

Rolf WeilDep. of Mat. & Metal. Eng.Stevens Inst. of TechnologyCastle Point StationHoboken, NJ 07030(201) 420-5257

Roy WeinsteinInstit. for Particle Beam DynamicsUniversity of HoustonHouston, TX 77204-5502(713) 743-3600

Elizabeth G. WeissMembrane Technology and Research, Inc.1360 Willow Road, Suite 103Menlo Park, CA 94025(925) 328-2228

James WertMech. Eng. Dept.Vanderbilt UniversityStation B, P.O. Box 1592Nashville, TN 37235(615) 322-2413

Sheldon M. WiederhornNational Institute of Standards and TechnologyBldg. 223, #A329Gaithersburg, MD 20899(301) 975-2000

Daniel E. WileyDir. of Improved Energy Prod.EE-231/FORSU.S. Dept. of EnergyWashington, DC 2085(202) 586-2099

Frank WilkinsEE-2A/FORSU.S. Dept. of EnergyWashington, DC 20585(202) 586-1684

A. D. WilksSignal UOP Research Center50 UOP PlazaDes Plaines, IL 60016(312) 492-3179

Lane WilsonNational Energy Tech Lab (NETL-MGN)Gas Power Projects Division3610 Collins Ferry RoadMorgantown, WV 26507-0880(304) 285-1336

C. E. WitherellLLNLUniversity of CaliforniaP.O. Box 808Livermore, CA 94550(925) 422-8341

J. C. WithersMat. & Electro. Res. Corp.7960 South Kolb RoadTucson, AZ 85706(602) 574-1980

D. E. WittmerS. Illinois Univ./CarbondaleDept. of Mech. Eng. & Egy Pro.Carbondale, IL 62901(618) 536-2396, ext. 21

T. WoleryLLNLUniversity of CaliforniaLivermore, CA 94550(925) 423-5789

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Stanley M. WolfEM-54/GTNU.S. Dept. of EnergyWashington, DC 20545(301) 903-7962

J. R. WootenRocketdyne6633 Canoga AvenueMail Code BA-26Canoga Park, CA 91303(818) 710-5972

John D. WrightTDA Research, Inc.12345 West 52nd AvenueWheat Ridge, CO 80033(303) 940-2301

R. N. WrightMaterials Technology Div.Idaho National Eng. LaboratoryIdaho Falls, ID 83415(208) 526-6127

Thomas M. YonushonisCummins Engine Co., Inc.Box 3005Mail Code 50183Columbus, IN 47202-3005(812) 377-7078

J. YowLLNLUniversity of CaliforniaLivermore, CA 94550(925) 423-3521

Dingan YuSupercon, Inc.830 Boston TurnpikeShrewsbury, MA 01545(508) 842-0174

Charlie YustORNLP.O. Box 2008Bldg. 4515, 063, Rm. 106Oak Ridge, TN 37830(865) 574-4812

C. M. ZehFETC P.O. Box 880Morgantown, WV 26505(304) 291-4265

Kenneth ZwiebelNREL1617 Cole BlvdGolden, CO 80401(303) 384-6441

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APPENDIX

Appendix

206EMaCC Charter Memo

04/18/03

CHARTER FOR THE DOE ENERGY MATERIALS COORDINATING COMMITTEE (EMaCC)

The DOE Energy Materials Coordinating Committee (EMaCC) is a working group reporting to the Director of the Office ofScience in the materials research and development aspects of the Director's statutory role (42 USC 7139b2 et seq.) asadvisor to the Secretary of Energy in monitoring the Department's energy research and development program.

The purpose of the EMaCC is to:

(a) Achieve more effective coordination of DOE materials research and development;(b) Assure optimum use of DOE's existing expertise in the field of materials research and development;(c) Achieve the most rapid communication among the DOE program representatives of new developments,

opportunities and problems in the area of materials research and development; and(d) Provide an infrastructure to facilitate DOE responses to external agency inquiries regarding DOE materials

research and development.

The EMaCC shall have the following charter:

I. SCOPE

Materials research and development is defined as research on solids or liquids. Specific topical areas for inclusionor exclusion shall be left to the Committee's judgment. Both applied and basic research are included in the scope.Particular emphasis in the basic research area is placed on those topics interacting with applied efforts although itis recognized that all basic research on materials is not immediately relevant to the applied programs. In the appliedprograms, emphasis is placed on materials development and materials engineering. It is recognized that this mayinclude economic or scale-up materials problem areas in energy systems. Raw materials and gaseous materialsare not to be emphasized by the EMaCC in order to more effectively focus the Committee's objectives.

II. RESPONSIBILITIES

A. Exchange of program, budgetary and planning information: The EMaCC members shall keep theirrespective divisions or offices informed of pertinent information concerning other division programs.

B. Technical information exchange: Members of the Committee shall provide and receive information to keepinformed of the state of materials research and technology.

C. Evaluations: The EMaCC shall identify areas of increased emphasis or areas of opportunity as the needarises; or respond to requests of the Secretary, Assistant Secretaries or the Director of the Office ofScience. The EMaCC Chair shall report annually to the Director of the Office of Science with anadministrative report and shall provide a copy of this report to the Executive Secretary for retention in theEMaCC file.

D. Reporting: The EMaCC shall keep minutes of each meeting and shall circulate them to all interested DOEpersonnel. The EMaCC or its members shall report on its activities as the need arises to Office or DivisionDirectors. When appropriate, the Committee may bring certain matters to the attention of the Director ofthe Office of Science.

E. Annual Technical Report: The EMaCC annually shall publish and distribute an Annual Technical Reportsummarizing all DOE materials research and development programs.

F. File storage shall be provided by the Division of Materials Sciences and Engineering in the Office ofScience. Web hosting will also be provided with the expectation that all involved parties will establishappropriate links.

III. MEMBERSHIP

The EMaCC shall include members from any DOE organizational unit having a substantial interest in materials. Anorganizational office is defined as any division or office having programmatic responsibilities. Representatives fromother federal agencies and from the DOE laboratories may be invited to attend as needed or when appropriate.Employees of DOE laboratories and employees of other organizations with which DOE has contracts mayparticipate as members of EMaCC, except on funding issues which are "not for public release," when assigned to

Appendix

208

participate in EMaCC while on detail to DOE headquarters in Washington, DC and Germantown, MD. Membershipin EMaCC shall be at the discretion of Division/Office Directors.

Any member of EMaCC in attendance at EMaCC meeting is deemed a voting member with regard to any businessconsidered at an EMaCC meeting except for those items specifically reserved to Voting Representatives of themember divisions/offices participating in EMaCC.

The Directors of each Division/Office participating in EMaCC shall designate a member of the staff of thatDivision/Office to serve as a Voting Representative for EMaCC. Each participating Division/Office shall have onevote. The Voting Representatives will be responsible for electing the Chair and Executive Secretary, for approvingall revisions of the Charter and for voting on any other matters that the members of EMaCC may refer to them.

IV. OFFICERS

The EMaCC shall have a Chair and an Executive Secretary to carry out the administrative functions of theCommittee. The Chair shall be a Voting Representative. The Executive Secretary need not be a VotingRepresentative of EMaCC. The Chair and Executive Secretary shall serve for a term of one year and shall benominated by committee of EMaCC approved at a duly convened EMaCC meeting. The Chair and ExecutiveSecretary shall be elected by the Voting Representatives during the fourth quarter of the fiscal year to serve for thenext fiscal year. A quorum of ten Voting Representatives, with at least four of the Voting Representatives fromdivisions in different assistant secretarial offices, shall be required to elect the Chair and Executive Secretary.

The duties of the Chair shall include:

A. Convening and leading EMaCC meetings

B. Representing the EMaCC as appropriate and involving other EMaCC members in reporting to DOEmanagement and

C. Assuring that the EMaCC abides by this Charter

The duties of the Executive Secretary shall include:

A. Serving in the absence of the Chair

B. Publishing and distributing the meeting notices and minutes

C. Retaining the EMaCC files

D. Publishing the EMaCC Annual Technical Report

V. TOPICAL SUBCOMMITTEES

Topical Subcommittees are responsible for conducting seminars and otherwise facilitating information flow betweenDOE organizational units with interests in the Subcommittees' respective materials subjects. The functions of theSubcommittees are:

(a) Coordination of efforts in key DOE materials areas(b) Participation in appropriate interagency meetings in areas of interest(c) Recommendation of issues and actions to entire EMaCC as appropriate(d) Provision of input to EMaCC Annual Technical Report

A new Topical Subcommittee can be created at the initiative of any member of EMaCC and with the approval of aduly constituted meeting of EMaCC.

Topical Subcommittee Chairmen shall be appointed by the Chair. The Topical Subcommittee Chairmen shall serveas an advisory committee for the purposes of program planning and preparation of the Annual Technical Report.Each Topical Subcommittee Chair shall prepare an brief annual administrative report to the EMaCC Chair with acopy to the Executive Secretary.

Appendix

209

VI. MEETINGS

The EMaCC shall determine the frequency with which to hold meetings, provided that Committee shall meet atleast three times a year. The Committee shall determine the time, place, and agenda for the next meeting.

VII. EMaCC ANNUAL REPORT

EMaCC shall published an Annual Report providing budgetary, programmatic and project information about thevarious non-classified materials-related programs in DOE. In addition, the Annual Report shall contain brief reportson the activities of EMaCC and other DOE materials activities which EMaCC may deem appropriate to include inthe report.

During the months of August or September, the Executive Secretary shall request the submission of budgetary,programmatic and project information pertaining to materials activities of the divisions participating in EMaCC.Divisions will be requested to provide such information by the November 1 in order to assure timely preparation andpublication of the Annual Report.

The Executive Secretary shall be responsible for maintaining a current distribution list for the Annual Report.

VIII. REVISIONS AND AMENDMENTS

Revisions or amendments of the charter may be proposed by any member of EMaCC for consideration at dulyconvened meeting. Copies of the proposed revisions or amendments most be provided to the members of EMaCCat least thirty days prior to the meeting in which they will be considered. Upon consideration and approval by two-thirds of those present at an EMaCC meeting, the proposed revisions or amendments shall be presented to theVoting Representatives for approval. Upon approval by two-thirds of the Voting Representatives responding in anEMaCC election, the revisions or amendments shall be accepted.

Index

210

INDEX

AAb-Initio (162)Ablator (166)Abrasion (183)Abrasive Waterjet Cutting (86)Absorption (163)Accelerated Aging (165)Actinides (131)Adhesion (158)Adhesive Bonding (30)Adjustable Speed (93)Advanced Composite Materials (69, 70)Advanced Computational Techniques (72)Advanced Heat Engines (24)Advanced Insulation (15)Advanced Materials (39, 67, 72)Advanced Nuclear Reactor (146)Advanced Processes (39)Advanced Reactor Process (51, 55)Advice System (94)Aerogels (15, 70)AFM/FTIR (164)Aftertreatment (26)Aging (138-140, 157, 164, 165)Agriculture (69)Air Compressors (27)Algorithms (164)Alkali (83)Alkaline (83)Alloys (24, 39, 55-57, 59, 65-71, 73, 123, 171, 173, 174,

176, 177, 180, 181, 183)Alumina (51, 52, 85)Alumina Crucible Cell (49)Alumina Electrolysis Cells (57)Aluminides (172, 176, 177, 182)Aluminum (26, 29, 30, 38, 49, 53, 54, 58, 64, 73, 81, 84)Aluminum Carbothermic Reduction (51)Aluminum Extrusions (53)Aluminum Melting (50, 57, 91)Aluminum Potroom Operation (50)Aluminum Production (49, 50, 58)Aluminum Refining (50)Aluminum Wheels (92)Amorphous Materials (75)AMTEC (137)Analytical Microscopy (76)Anisotropic Rapidly Solidified Permanent Magnet

Powders (107)Anistropic Magnets (107)Annealing (53, 59)Anodes (55, 84, 85)Application Control (92)ASME Code (139)Assessment (29)ASTM (37)Atomic Force Microscopy (165, 166)

Atomic-Level (157)Austenitic Stainless Steel (36, 139)Austenitics (161, 173, 174, 176)Automated In-Line Heat Treatment (91)Automotive (24, 29, 31, 38)

BBack-Surface Field (77)Bacterial Cellulose (45)Bar Edge (91)Batteries (86, 156)Benign Technology (90)Beryllium (166)Billet (73)Biomimetics (76)Biomineralization (165)Biopulping (90)Bipolar Plates (44)Birefringent (154)Bismuth Conductor (21)Black Liquor (62)Boilers (61, 62, 86, 94)Bonded Magnets (BH)max (107)Bonding (70)BOR-60 (142)Borides (69)Boron (50, 142)Brakes (29, 38)Brazing (152)BST Thin Films (108)Buffer Layers (18)Building Materials (14, 81)Buildings (14, 84)Buses (38)BWR (140)Byproducts (61)

CCadmium Telluride (75)Calcination (132)Calibration (64)Campaign 8 (165)Canned Subassembly (165)Capacitor (86)Carbon (24, 27)Carbon Anode (50)Carbon Dioxide (65)Carbon Materials (25, 26, 28, 38, 39, 44, 68, 108, 137,

173, 174)Carbon Monolith (38)Carbonaceous Fines (83)Carbothermal Reduction (36)Carburization (71)Cast Metals (29, 63, 64, 85, 91, 183)

Index

211

Casting (29, 38, 56, 57, 59, 64, 65, 67, 71, 73, 112, 183)Catalysts (27, 33, 69, 113)Cathodes (55, 58, 65, 84)Cells (85)Cements (42)Ceramics (26-28, 34, 39, 57, 62, 65, 67, 68, 70, 81, 82,

85, 87, 128, 152, 156, 172, 174, 175, 177, 178)Cermets (28, 32)CFC (13)Characterization (70)Chemical Analysis (66, 162, 164)Chemical Industry (65)Chemical Vapor Deposition (66, 70, 75, 111)Chemiresistance (154)Chlorine (52)Chromium-Niobium (173)Chromophore (160)CIDI (28)Claddings (65, 136)Clathrate-Like (162)CO2 Emissions (112)Coated Conductor (18)Coatings (28, 44, 65-70, 73, 75, 108, 123, 172-175, 177,

182)Coking (73)Collective Phenomena (162)Collectors (88)Colloids (158)Combinatorial (71)Combustion Tuning (94)Commercial Hydrogen Peroxide Process (89)Compatibility (123)Components (39, 178)Composites (39, 70, 91, 124, 154, 172-175, 177)Computational Materials Science (161)Computational Modeling (71)Concentrator Cells (76)Concrete (57, 61, 133)Condition Monitoring (139)Conductive Polymers (76)Conference (180)Contact Damage (37)Containers (92)Contaminants (133)Continuous Casting (53, 54)Continuous Fiber Ceramic Composites (73)Controlled Distance Electrochemistry (143)Coolant Behavior (60)Coordinate Measurement (87)Coordination (24)Copper (75, 86, 88, 92)Core-Concrete Interaction (148)Corrosion (37, 41, 44, 60, 61, 65-73, 91, 112, 130, 133,

143, 145, 157, 159, 160, 172-177, 182-184)Cost (26, 29, 39)COTS (160)Coupling System (93)Crack Growth (143, 146)Crack-Tip (146)Cracking Unit (90)

Crashworthiness (30)Creep Resistance (62, 73)Creep Rupture (176)Cryolite (51, 55)Crystallization (53, 69, 75, 77, 165)CSA (165)Cullet (81)Current Controller (20)

DDeep Ultraviolet Lithography (111)Defects (177)Degassing (59, 67)Degradation (156, 157, 159)Delocalization (160)Deposition (18, 61)Design Provisions (53)Diamond Composites (69)Die Casting (29, 30, 63, 64, 69, 81, 91, 92)Dielectric (108)Diesel Engines (26, 28, 33, 85)Diffraction Grating (131)Digester (61)Dilatometry (67)Dip-Pen Nanolithography (166)Direct Chill Casting (54, 58, 60)Dislocation (108, 158, 160)Dissimilar Materials (29, 39)Drilling (35)Dross (50)DSC (67)Dual Pressure (93)Ductile Cast Iron (36)Ductility (69)Duplex Stainless Steel (64)Durability (30, 31)Dye-Sensitized Cells (76)Dynamic Cyclone Classification (82)Dynamic Windows (15)

EEarth Salts (83)Eddy-Current (138)EDM (35)EGR (37)EIS (145)Electrical Insulation (138, 139)Electrically Conducting Polymers (65)Electrochemical Impedence Spectroscopy (145)Electrochemical Reactors (65)Electrochemical Sensor (28)Electrochromic (15, 84)Electrodeposition (75, 155, 157)Electrolytic Cells (52)Electrolytic Reduction (55)Electromagnetic Forming (29)

Index

212

Electrometallurgical (52)Electron Beam Processing (109)Electron Microscopy (77, 164)Electronics (26)Electroplating (152, 163)Electrowinning (85)Embrittlement (148)Emissions (56, 92)Emitter (85)Encapsulants (152, 156)Energetic Materials (165)Energy Storage (86)Engineered Barrier System (168)Engines (26)Enhanced Surveillance (165)Environmental Fatigue (139)Erbium (142)Erosion (66, 183)Ethylene (73, 85)Eutectic Salts (82)EUV (165)Exhaust Aftertreatment (32, 33)Exhaust Emissions (33)Exhaust System (36)Exhibits (180)Extrusion (29, 38, 56, 73)

FFailure Analysis (26)Fatigue (139)FCU Technology (90)Feedstock (57)Ferritic (68, 148, 161)Ferroelectric (108, 156, 161)Ferromagnetism (66)Ferrous Alloys (66)Fiber Optics (139)Fiber Sensor (88)Fibers (30, 42, 70, 172, 177)Fibrils (174)Field Structuring (154)Film Formation (112)Film Silicon (75)Filters (26, 177, 178)Fine Minerals (90)First-Principles Modeling (158)Flaws (175)Flexural Strength (37)Flocculation (88)Flotation (49, 88)Fluence Calculation (140)Fluid Catalytic (90)Fluidized-Bed Combustion (176)Fluorescent Lighting (85)Fluted Spiral Membranes (86)Flux Pinning (21)Flywheel (20)Foams (13, 152)

Focal Project Design (31)Foil-Lamination Process (182)Forest Products (69, 87, 88)Forging (69, 87)Formability (57)Forming (30, 38)Foundries (87)Foundry Coke (83)Foundry Sand (87)Fourier Transform Spectroscopy (77)Fracture (37, 57, 69, 71, 141, 175, 177)Fracture Surface Topography Analysis (143)Frames (38)Friction (27, 35, 37-39, 108)Friction Materials (38)Fuel Cells (27, 34, 44, 45, 175)Fuel Injection (28, 37, 108)Fuel Particles (147)Fuel Systems (31, 32)Fungus (88)Furnace (60, 73, 85)Fusion Zone (153)

GGadolinium (111, 142)Gallium Arsenide (76)Galvanizing (29, 89)Gas Fluxing (52)Gas Separation (65)Gas-Fired Furnaces (86)GaSb Cells (87)Gasification (62, 176)Gasochromic (15)Gelcasting (26, 28)Generation Efficiency (93)Generation IV (144)Generator (20)Geologic Repository (128)Geothermal Piping (41)Geothermal Wells (42)Gettering (152, 163)Glass (60, 65, 69, 72, 82-86, 88, 91, 128, 132)Glass Fiber (88)Glazing (31)Grain Boundary (157, 160)Grain Refinement (67)Graphite Iron Casting (83)Gray Iron (64)Grinding (35)Guided Waves (41)

Index

213

HHall-Héroult (55, 85)Hamiltonians (158)Hard Coatings (26)Haynes 25 (137)HCFC (13)HDI (68)Heat Checking (64)Heat Exchangers (28, 38, 77, 93, 182)Heat Sinks (25)Heat Transfer (25, 28)Heat Treating (66, 69, 71, 86, 91)Heat-Air-Moisture (14)Heavy Vehicle (38)HEDM (141)High Density Infrared Heating Technology (70)High Energy Density Material (141)High Explosives (165)High Luminosity (91)High Pressure Deposition (85)High Pressure Techniques (69)High Purity Silica (82)High Rate Processing (31)High Strain Rate (157)High Strength Steel (30)High Temperature (60, 72, 136)High Tensile Strength (68)High Volume Processing (30)High-Efficiency Silicon Cell (77)High-Efficiency Solar Cells (76)High-Level Waste (132)High-Speed Imaging Techniques (107)Hot Corrosion (183)Hot Mill (91)Hot Rolling (53, 54)Hot-Gas (173)HotEye (87)Humidity (160)Hydriding (145)Hydrocarbon (93)Hydroceramic (132)Hydrochloric Acid Recovery (89)Hydroforming (29)Hydrogen Effects (140, 152)Hydrogen Passivation (77)Hydrogen Peroxide (89)Hygrothermal (14)Hyperspectral Image (159)

IIBEST (142)Ice-Like (162)IEA (37)IFBA (142)IGSCC (145)III-V Materials (76)

Immersion Heater (59)Impact-Echo Instrumentation (88)In-Situ Surface UV-Raman Spectroscopy (113)Incandescent (85)Inclusions (64)Industrial Applications (93)Industrial Boilers (72)Industrial Chemicals (73)Industry (70)Inert Anodes (49, 51, 57, 84)Inert Cathode (84)Infrared (IR) (65, 68, 70, 165)Infrastructure (29)Ingot Casting (54)Ink-Jet Printing (153)Inorganic Membranes (44)Inserts (64)Inspection (35)Insulation (14)Insulation Sheathing (13)Insulation/Thermal (136)Integral Fuel Burnable Absorbers (142)Intelligent Data Analysis (155)Interfaces (108, 163)Interfacial Fracture (161)Intergranular Stress Corrosion Cracking (143, 145)Intermetallic (32, 65, 66, 173)Ion Beam Surface Treatment (142)Ion Exchanger (129)Ionic Fluids (15, 55)Iridium Processing (136, 137)Iron Aluminides (65)Iron Phosphate Glass Fibers (84)Iron Phosphate Glasses (128)Irradiation (123, 124, 138-140, 142, 144, 147, 148)Isomer (141)Isothermal Melting Process (59)

JJoining (29, 39, 65, 66, 70, 161, 176, 182)

KKiln Monitor (87)Kraft Recovery Boilers (87)

LLamellar Microstructure (36)Langmuir Probe (158)Laser Fusion Targets (166)Laser Light Beam (88)Laser Surface Alloying (69)Laser Welding (153)Laser/Material Interaction (153)LED (83)Life Prediction (26, 33, 35, 165)

Index

214

Lifetime (157)LIGA (155, 163)Light Trapping (77)Light Water Reactor (LWR) (142, 144, 146)Lightweight (38, 92)Liners (183)Liquid Vapor Separations (65)Liquid-Phase Epitaxy (76)Lithium (123)Lithium Ion Battery (156)Lithography (152)Localized Reinforcement (85)Lost Foam Casting (63, 82, 92)Low Btu Gas (90)Low Cost Carbon Fiber (31)Low Profile Fluid (90)Low Temperature Electrolysis (51)Low Dross Combustion (52)Lubricants (92)Lumber Drying (87)

MMachining (35, 63, 64)Macrostructure (144)Magnesium (29, 30, 38, 39, 83, 87, 93, 112)Magnetic Elutriation (89)Magnetic Fields (66, 158)Magnetic Resonance (20, 84)Magnetocaloric Effect (111)Magnetohydrodynamic (55)Magnetoresistance (154)Management (24, 179)Manufacturing (32, 38, 44, 152)Martensitic (148)Master Curve (141)Material Characterization (137)Material Testing (42)Materials (37, 39, 65, 66, 70, 72, 73, 173, 178, 181, 182)Materials Program (179)MBE (76, 77)Measurements (70)Mechanical Properties (26, 35, 42, 68, 70, 72, 93, 139,

157, 173)Melt Coolability (148)Melting (56, 153)Melting Extrusion (136)Membranes (27, 45, 65, 73, 82, 178-180)MEMS (153)Mesoporous Materials (61, 70)Metal Casting (63-66, 69, 81, 82, 91, 92)Metal Deposition (109)Metal Matrix Composite (29, 81)Metal/Ceramic Interfaces (158)Metals (24, 54, 66, 67, 70, 73, 82, 83, 112, 133, 152)Micro-Turbine (90)Microdevices (154, 163)Microelectrodes (159)Microfabrication (152)

Micromachining (111, 155, 163)Microporous Materials (51)Microscopy (69, 158)Microsmooth Process (92)Microstructural (33, 57, 59, 66, 67, 71, 142, 144, 148,

152, 157, 161, 172)Microsystems (156, 157)Microtexture (54)Microwave (26, 31, 52)Milling (35)Mineral Flotation (86)Mineral Processing (89, 90, 130)Mining (69, 86, 88, 89)Minority Carrier Lifetime Measurement (76)MMC (39)MOCVD (76, 77)Modeling (60, 70, 72, 123, 133, 139, 140, 157, 174, 175)Module Testing (76)Moisture (14)Mold Surface Topography (56)Molds (69)Molten Glasses (131)Molten Salts (183)Molybdenum (137, 171)Monitoring (60, 88)Monolayer (162)Monolithics (70, 73)Motor (20, 92)Multi-Gas Analyzer (94)Multicrystalline Silicon (77)Multilayer Technology (26, 63, 165)Multivariate Analysis (164)Multivariate Calibration (159)

NNanocrystals (76)Nanolayers (154)Nanolithography (109, 160)Nanomaterial (34, 158, 160)Nanonstructural (69, 76, 77, 142, 153, 155)Nanoporous (70)Nanoscale (156)Nanoscale Patterns (166)Natural Gas (38, 65)NDE (29, 34)NdFeB (25)Near Frictionless Coating (27)Near-field (128)NEET (141)Net Shape (93)Neutron Residual Stress (70)New Materials (108)NEXAFS (156)Next-Generation Photovoltaics (76)NiAl (32)Nickel Alloy Substrate (110)Nickel Aluminide (36, 65, 66)Nickel-Plating Process (92)

Index

215

Niobate (129)Nitride (44)NMR (156)Non-Destructive Examination (138, 140)Non-Destructive Testing (34, 41, 76, 82, 175)Non-Equilibrium Microstructures (163)Non-Invasive (85)Non-Nuclear Materials (165)Nonthermal Plasma (26)NOx (28, 32, 33)Nozzles (28)Nuclear Fuel Development (142)Nuclear Waste (128)Nuclear Weapons (165)Nucleation Density (111)Numerical Modeling (30, 73)Nut Orchard Processing (90)

OOil and Gas Production (93)Optic Systems (165)Optical Fiber (82)Ordering in Semiconductors (77)Organic Solar Cells (76)Orifice (28)Overlay (176)Oxidation (56, 110, 142, 145, 183)Oxide Dispersion Strengthened Alloys (182)Oxide Sludge (50)Oxy-Fuel (60)Oxy-Gas Burners (91)Oxygen (65)

PPackaging (163)Pallets (84)Paper Mill (89)Papermaking (90)Paramagnetism (66)Particle Formation (61)Particle Size (131)Particulate Emissions (33)Passivated (157)Passive Elecrtonic Devices (165)Passive Heating (14)Pecan Shells (90)PEM (44)Permanent Magnets (25, 107)Petrochemical (94)Petroleum (82, 93)Phase Change (14)Phase Equilibria (132)Phase Stability (130)Phase Transition (161)Phosphors (83)Photocatalysis (109)

Photochromic (154)Photoelectrochemical Materials (77)Photonic (154, 156)Photosensitive (154)Photovoltaic (84, 85-87)Physical Vapor Deposition (75)Pickle Liquor (89)Piezoelectric Actuators (31, 32)Piezoresistance (154)Pipe Support Inspection (94)Piping (14)Pits (165)Planning (39)Plant Reliability (41)Plasma (66, 124, 127, 158, 166)Plasma Spraying (34)Plastic Deformation (60)Plastic Manufacturing (91)Platinum Membrane Electrode Assemblies (27)Plutonium (127, 165)PMD (145)Point Defects (77)Point Model Defect (145)Polycrystalline Films (75)Polyimide (166)Polymers (29-31, 39, 76, 86, 88, 138, 154, 166)Porosity (63, 68, 73)Post-Consumer Durable Goods (91)Potlining (50)Pour In Mold (83)Powder Synthesis (36)Power Electronics (25)Power Plants (181, 182)Precision Thin Films (165)Precursors (31)Predictive Properties Control (108)Pressurized Ozone Membrane Ultrafiltration (89)Primary Aluminum (51, 52, 56)Process Water (89)Processing (31, 66, 70, 155, 172)Properties (14, 60, 70)Proton Conductivity (44)PT Loads (42)Pulp and Paper (61, 62, 70, 86, 88)PWR (140)Pyramid Molds (111)Pyrolysis (68)PZT 95/5 (161)

QQuantum Mechanical (162)Quaternary Semiconductors (76, 77)Quench Wheel (107)

Index

216

RRABiTS (110)Radar Technology (88)Radiation (128, 156)Radiators (28)Radio Frequency Magnetron Sputtering (110)Radioactive Waste (131)Radiolysis (145)Radiolytic Decomposition (145)Radionuclides (130, 133)Random Grain Boundary Network (143)Rapid Prototyping (30)Rapid Solidification Process (107)Rapid Thermal Processing (75, 77)Rapid Tooling (63)RBNC (143)Recouperator (91)Recovery (61, 62, 70)Recrystallization (53)Recycling (31, 57)Refine Materials (83)Refractory (59, 60, 62, 65, 68, 70, 72, 73, 83, 178, 183)Refractory Metals (124)Refrigerators (13)Reinforcement (64)Reliability (156, 165)Removal (61)Resistant Materials (92)Reverberatory Furnaces (52, 57)Reverse Osmosis (86)Rhenium (137)Rheology (154)Rod Mill (94)Rolling (56)Rolling Contact Fatigue (37)Roofs (13)Rotating Equipment (68)RPV (141)

SSalt Cake (57)Salt Fluxing (56)Sand Casting (92)Sand Mold (64)Sandwich Panels (81)SCR (32, 33)Scrap Reduction (92, 93)Screen Printing Metallization (77)Scuffing (27, 35, 37)Seals (180)Secondary Aluminum (52)Self Assembly (109, 153)Semi-Solid Molding (93)Semiconductor Materials Measurement (77)Semiconductor Microstructure (76)Semiconductor Processing (111)

Semiconductors (75, 76, 77)Sensors (32, 33, 57, 87, 152, 153, 155, 164)Separation (20, 73, 82, 86, 87, 178)Sheet Forming (29)Shock Response (156)Shock Wave Depoling (161)Shot Sleeves (91)SiC (68, 69, 147)Sieves (173)Silica-Based Glass Fibers (84)Silicon (83, 75, 111, 124, 171)Silicon Nitride Passivation (77)Silicon Wafers (111)Silicotitanate (129)Silver-Clad (Bi,Pb)2Sr2Ca2Cu3Oy (107)Simulation (29, 123)Sintering (68, 152, 156)Sintering Glass Powder (81)Slagging Gasifier (183)Slurry (131)Smelting (49, 50, 55, 73)Sodium-Bearing Waste (132)Soft Ceramic Particles (82)Soft Solution Processes (158)Sol Gel (70, 73)Solar Cells (75-77, 84)Solar Concentrators (84)Solar Control (15)Solar Heat Gain Coefficient (15)Soldering (152)Solid State Spectroscopy (77)Solidification (161)Solvents (69)Sorting Plastics (91)Spatter (153)Spectroscopy (131, 164)Spectrum (85)Spot Welding (30)Spray Forming (58)Sputtering (75, 166)Squeeze Casting (64)Stamping (30)Standards (37)Steam Generator (138)Steam Turbine (93)Steel (38, 63, 66, 67, 71, 90, 123, 148)Steel Industry (65)Steel Inspection (94)Stochastic Optimization Algorithms (71)Stockpile (165)Strain and Water Chemistry (72)Strain Rate (30)Stresses (70, 72, 138, 140, 146)Structural Characterization (42, 164)Structural Components (24, 39, 81)Structural Reliability (31)Sulfides (86, 160)Superconducting Materials (21, 25, 107)Superconductor (18)Supercritical Water (145)

Index

217

Superhard Materials (69)Superlattices (154)Superplastic Forming (38)Supersaturation (155)Surface Behavior (54, 76, 90, 163)Surface Coatings (63)SXR and XR Optics (165)Synthesis (61)Systems (165)

TTechnical Management (29, 39)Technology Transfer (174)TEEN (141)TEM (27, 33)Temperature Measurement (35)Templates (155, 166)Ternary Semiconductors (76)Testing (179)Textured Substrate (18)Textures in Aluminum Alloys (53)Thallium Conductor (21)Thermal Barrier Coatings (34)Thermal Gradient (184)Thermal Management (25)Thermal Properties (68, 72, 137, 142)Thermal Spray (65, 152)Thermal Storage (14)Thermochemical (72)Thermocouples (183)Thermodynamics (56, 65, 68, 69)Thermomechanical Processing (55)Thermomechanical Properties (65)Thermophotovoltaic (87)Thermophysical Properties (65, 67)Thermoresistance (154)Thin Films (34, 156)Thin-Walled Container (92)TiC (32)Tiles (14)Time-Dependent (157)Titanium (27, 35, 36, 39, 58, 81, 84, 112, 183)Titanium Matrix (91)Topographical (157)Total Dissolved Solids (89)Traction Motors (25)Traction-Separation (161)Transmission Cable (20)Transport (133)Tri-Crystals (77)Tribology (35, 56, 108, 155, 157, 163)Trifluoroacetate Solution Process (110)TRISO (147)Trucks (38)TTBC (34)Tubes (72, 73, 180)Turbines (94, 181, 182)Turning (35)

UUHF (90)Ultrafine Grained Material (60)Ultrananocrystalline Diamond (66)Ultrasonics (41, 59, 67, 94, 131)Uranium Oxides (130)User Center (70)UV (165)

VVacuum-Arc Plasmas (158)Valves (33)Vanadium (90, 123)Viscosity (131)Visible (165)Vision 21 (182)Vitrification (128)Void Swelling (144)Voltage (49)

WWall Recession (88)Waste Package (168)Waste Streams (57)Water (45, 162)WC (65)Wear (26, 27, 67, 90, 183)Welding (30, 65, 66, 68, 70-73, 140, 152, 176)Welding and Brazing (137)Wetted Cathode (51)Whiting (90)Window Film (84)Wood Chip Penetration (88)Wood Sorting (84)Wood Speciation (84)Wood-Waste Boiler (86)Workshops (39)

XX-Ray (152)X-Ray Absorption (131)

YYucca Mountain Repository (168)

Index

218

ZZeolite Based Materials (73, 113, 131, 132)Zero Emission (93)Zinc Alloys (62)Zinc Die Casting (62)Zircaloy (145)ZnO (155)

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ENERGY MATERIALS COORDINATING COMMITTEE (EMaCC)