NETL researchers have developed a process to manufacture a class of high-performance alloys for use in a variety of applications, including the export of liquefied natural gas (LNG) from the United States to international markets.

In their study, published in the journal Acta Materialia, NETL researchers outlined their development of a novel multi-length-scale approach that provides a pathway to produce high-strength model and commercially available nickel-, cobalt- and chromium-containing alloys.

Traditionally, single-phase alloys that have good corrosion properties and malleability (the ability of a material to be hammered or rolled into thin sheets) have relatively low strengths, which limits their application. The new method was developed to process this class of alloys and improve and even tailor their properties to withstand high-pressure, high-temperature environments.

“One of the emerging uses for this new process is to develop alloys that can help the United States supply international markets with LNG by making it easier to safely transport this domestic resource to places pipelines do not reach,” said NETL researcher Stoichko Antonov.

Natural gas is liquefied by cooling or compressing it so it can be stored and shipped in special tankers to terminals around the world. At these terminals, LNG is returned to its gaseous state and transported by pipeline to distribution companies, industrial consumers and power plants.

The process developed by NETL focuses on using nickel-, cobalt- and chromium-containing alloys to provide superior strength and corrosion resistance at temperatures down to minus 150 degrees Celsius.

In the new process, researchers determined that techniques such as pre-straining and heat treatment improved resistance to deformation. The process also calls for the use of molybdenum, a key alloying agent in producing superalloys, to achieve desired changes in stacking fault energy, a material’s property that determines the deformation mode of materials.

“There is a growing trend to transport LNG at cryogenic temperatures. To address this, we have advanced a process with tremendous potential to develop a high-strength, corrosion-resistant class of alloys that can be used to build storage tanks and other infrastructure to safely transport and distribute LNG and fuels such as liquid hydrogen, which cause metals to become brittle or corrode,” Antonov said.

The NETL-led breakthrough in materials development could help the United States meet its goals for LNG exports. Upon taking office, President Trump reversed a Biden-era pause on new LNG exports and issued an order for the United States to resume processing export permit applications for LNG projects.

Trump’s sweeping executive order, which is aimed at unleashing affordable and reliable domestic energy to restore U.S. prosperity and rebuild the nation’s economic and military security, lifted the pause on new LNG project reviews.

NETL is a U.S. Department of Energy (DOE) national laboratory dedicated to advancing the nation’s energy future by creating innovative solutions that strengthen the security, affordability and reliability of energy systems and natural resources. With laboratories in Albany, Oregon; Morgantown, West Virginia; and Pittsburgh, Pennsylvania, NETL creates advanced energy technologies that support DOE’s mission while fostering collaborations that will lead to a resilient and abundant energy future for the nation.