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Renewable Power Generation
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Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 780-788, May 4–6, 2022,
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Lead, lead-bismuth, or lead-lithium are candidate materials for liquid metal-based cooling media in the new generation of nuclear fission reactors and fusion systems. There are many benefits of using this concept; however, a new problem arises too: preventing degradation of structural materials that are supposed to come into a direct contact. Therefore, new steel grades are being designed, and technological workarounds are searched for. One of the pathways could be a deposition of thick, long-term stability protective coatings onto the steel surfaces. In our opening study, we have employed CS and RF-ICP technologies to deposit Mo and Fe coatings onto ferritic-type 9% Cr Eurofer steel and its ODS variant, and tested them in the PbLi environment at 600 °C for up to 1000 hours. The results suggest that the Fe coatings showed a promising resistance to the corrosive medium and are worth studying deeper.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 789-797, May 4–6, 2022,
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A solid oxide fuel cell is an electrochemical conversion device that produces electricity directly from oxidizing a fuel. It involves ionic transport and electrochemical reactions where the electrolyte and electrode properties play a major role in performance, along with a range of complementary materials that need to ensure equally relevant functions across the cell. The lifetime of such functional materials is expected to reach many thousands of hours with minimal degradation. This article is centred around the process development, optimization and scale up of a thin plasma sprayed ceramic barrier layer to mitigate long-term performance degradation of metal-supported solid oxide fuel cells. The evolution from the proof of concept in a laboratory environment to the scale up toward large scale manufacturing production is discussed. The challenges associated with minimizing application time and lowering cost while maintaining high coating performance at high yield are discussed. Empirical observations such as microstructural analysis and in-flight particle monitoring are used to gain understanding of the plasma spray process and guide its development for high-volume production. Results show how this effort has led to the reduction of the coating deposition time by 94% to enable large-scale manufacturing at high yield.
Proceedings Papers
ITSC 2022, Thermal Spray 2022: Proceedings from the International Thermal Spray Conference, 798-808, May 4–6, 2022,
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In nuclear fusion reactors, the first wall is the name given to the surface which is in direct contact with the plasma. A part of it is the divertor which is a device that removes fusion products from the plasma and impurities that have entered into it from the vessel lining. It is covered with water cooled tiles which have to withstand high temperatures and high heat fluxes. Moreover, resistance to neutron bombardment, low tritium absorption and low hydrogen permeation are additional demands. One materials concept under research is the application of a Reduced Activation Ferritic Martensitic Steel (RAFM) as a structural material with a tungsten protective coating. Since there is a considerable thermal mismatch between, a functional graded materials (FGM) concept was proposed. As the formation of undesired intermetallic Fe-W phases as well as oxidation should be avoided, cold gas spraying was chosen as manufacturing process. Two powder blends of EUROFER97 RAFM steel and a fine tungsten powder cut on the one hand and a coarser one on the other hand were tested in different ratios. The coatings were characterized with respect to their porosity and surface structure. Furthermore, the deposition efficiencies for steel and tungsten were determined each. It turned out, that the deposition process is a complex mixed situation of bonding and erosion mechanisms as the deposition windows of these very different materials obviously diverge. Thus, a lower working gas temperature and pressure was advantageous in some cases. Unexpectedly, the coarser tungsten powder in general enabled to achieve better results.