High Performance Materials & Modeling

Power generation plants operate under extreme conditions from a materials standpoint. Future advanced generation facilities will be expected to withstand harsher environments due to higher demands for increased efficiency, quicker plant startups and turndowns, cycling, and alternative power source supplementation. To support these expectations, new materials are needed for these conditions and performance expectations.

Advanced ultrasupercritical (AUSC) boilers, pressurized oxy-combustion boilers, pressurized gasifiers and the advanced turbines for each of these types of plants will operate under higher temperatures and pressures, which promote rapid corrosion and degradation of subcomponent materials. Internal material stresses in thick-walled components such as superheater headers, turbine casings, and turbine rotors, along with boiler tube scaling, and turbine blade erosion are critical material issues that must be addressed for reliable plant operation.

To meet challenges such as these, the Fossil Energy Materials Program, led by the National Energy Technology Laboratory (NETL) within the Office of Fossil Energy (FE) of the U.S. Department of Energy (DOE) is implementing research and development (R&D) with other national laboratories, industry, and academia. It covers the entire realm of materials from design through manufacturing to address materials requirements for all fossil energy systems, advanced power generation and coal fuels technologies.

Specific Technology Objectives

  • Development of computational materials modeling to enable rapid design and simulation of new and novel alloy materials with less repetitive testing. Computational design of materials has the potential to produce major breakthroughs
  • Development of superalloys and ferritic materials for use in AUSC conditions of 760°C and 350 bar pressure (5,000 pounds per square inch) to reduce costs, improve corrosion and erosion resistance, increase material strength, and reduce wall thickness.
  • Development of functional materials for energy storage and high-performance materials with mechanical properties that can perform reliably at temperatures well over 1,000ºC.
  • Development of advanced metallic and ceramic coatings, including nanomaterials, to provide thermal barrier protection for turbine blades, combustor components and tubing.
  • Validated computational models capable of simulating and predicting performance of materials in various types of transformational power plants, including pressurized oxy-combustion, pressurized gasification, and CO2 cycle plants.

NETL Materials research projects, success stories, AUSC program publications, Fact Sheets, and FE Materials program project review meetings proceedings can be viewed at:

  • Fossil Energy Materials Program Project Portfolio , U.S. Department of Energy, National Energy Technology Laboratory, April 2012
  • Materials Program Fact Sheets
  • FE Materials Program Project Review Meetings Proceedings
  • AUSC Program Publications

Alloy Selection for Rotors, Discs, and Blades

  • R. Viswanathan, J. Shingledecker, J. Hawk, S. Goodstine. “Effect of Creep in Advanced Materials for Use in Ultrasupercritical Power Plants.” Proceedings: Creep & Fracture in High Temperature Components, 2nd ECCC Creep Conference, April 21-23, 2009, Zurich, Switzerland.”© 2009 DEStech Publications, Ins. 31-43

Castings

  • P. Jablonski et al. “Processing of Advanced Alloys for A-USC Steam Turbine Applications,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.
  • P.J. Maziasz et al. “High Temperature Mechanical Properties and Microstructure of Cast Ni-Based Superalloys for Steam Turbine Casting Applications,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.

Cost and Economics

  • Phillips, J.N., and J. Wheeldon, “Economic Analysis of Advanced Ultra-Supercritical Power Plants,” 6th Int’l Conference on Advances in Materials for Fossil Power Plants, Santa Fe, NM, August 2010.
  • Viswanathan, R., J. Shingledecker, and J. Phillips, “In Pursuit of Efficiency in Coal Power Plants,” International Clearwater Coal Conference, Clearwater, Fl, June 2010.
  • Ciferno, J., “Pulverized Coal Oxycombustion Power Plants – Final Results,” NETL presentation, August 2008

Creep Strength and Long-Term Stability for Boiler Alloys

  • R. Viswananthan, J.F. Henry, J. Tanzosh, G. Stankl, J. Shingledecker, B. Vitalis, R. Purgert. “U.S. Program on Materials Technology for Ultra-Supercritical Coal Power Plants.” Journal of Materials Engineering and Performance. Vol. 14 (3) June 2005. 281-292
  • J.P. Shingledecker, I.G. Wright. “Evaluation of the Materials Technology Required for a 760°C Power Steam Boiler.” Proceedings to the 8th Liege Conference on Materials for Advanced Power Engineering 2006. Forschungszentrum Jülich GmbH (2006) pp. 107-120.
  • Viswanathan et al. Advanced Materials & Processes, August 2008, ASM International

Erosion and Oxidation of Blade Materials

  • T.C. Totemieir, S. Goodstine. “Oxidation of Candidate Alloys and Coatings for A-USC Steam Turbines,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.

Fabrication and Design

  • W. Mohn, G. Stanko. “Investigating the Strain Limits of Cold Formed, High Temperature Austenitic Materials for Fabricating USC Boiler Components.” Proceedings to the Fourth International Conference on Advances in Materials Technology for Fossil Power Plants (Hilton Head, SC, Oct. 25-28, 2004). ASM-International, Materials Park, OH 2005. 153-167
  • J.P. Shingledecker. “Creep Rupture Behaviour and Recrystallization in HR6W and Haynes Alloy 230 Cold Bent Boiler Tubing for Ultra-Supercritical Steam Boiler Applications.” Energy Materials, Vol. 2, No. 4, 2008. 235-240.

Fireside Corrosion

  • M. Gagliano, G. Stanko, H.Hack. “Methods for Assessing the Fireside Corrosion Resistance of Boiler Materials, Coatings, and Overlays,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.
  • E.S. Robitz, J.M. Tanzosh. “In Situ Corrosion Testing of Ultrasupercritical Tube and Weld Overlay Materials.” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010

Steam Oxidation and Exfoliation

  • J.M. Sarver, J.M. Tanzosh. “Characterization of Steam –Formed Oxides on Candidate Materials for USC Boilers.” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.

Welding and Repair

  • M.P. Borden. “Weldability of Materials for Ultrasupercritical Boiler Applications.” Proceedings to the Fourth International Conference on Advances in Materials Technology for Fossil Power Plants (Hilton Head, SC, Oct. 25-28, 2004). ASM-International, Materials Park, OH, 2005. 837-854.
  • J. Siefert, J. Tanzosh, J. Shingledecker, K. Coleman. “Weldability of EPRI P87,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.
  • M. Santella et al. “Creep Rupture Testing of Inconel®740 Weldments,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.
  • J. Siefert et al. “Weldability of Inconel®740,” 6th International Conference on Advances in Materials Technology for Fossil Power Plants, Santa Fe, New Mexico, August 30-September 4, 2010.
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