The Materials Science Focus Area specializes in life cycle research starting with the formulation, characterization, and melting of most metals, alloys, and ceramics; casting and fabrication; prototype development; and the recycling and remediation of waste streams associated with these processes. Advanced materials and processes are vital to higher performance and more economic fossil energy systems such as the FutureGen prototype power plant and other 21st century power and fuels production plants.

This focus area addresses the need for new materials that can withstand higher temperatures and corrosive environments of advanced power generation technologies such as coal gasifiers, turbines, combustors, and fuel cells.

The two materials research groups: Materials Performance and Process Development, combine the talents of NETL scientists, technicians, craftspeople, and experienced support personnel to make NETL a complete development and processing facility. From microstructure to pilot-scale processes, NETL works with industry, academia, and other government agencies on research to resolve a wide range of materials issues.

Materials performance research ranges from defining and understanding the basic mechanisms of wear and corrosion, and the synergy between them; to providing input on materials performance and specifications for specific operating environments; to developing methodologies for real-time materials performance monitoring in the field.

Researchers specialize in the understanding and assessment of materials performance issues, including:

• materials selection and specifications for high-temperature, erosive and corrosive environments
• real-time materials performance monitoring
• corrosion and wear mechanisms, and
• lifetime predictions.

Process development research targets the development of processes to:

• efficiently produce prototype parts, castings, and/or plate or sheet from ferrous, non-ferrous, and refractory alloys;
• formulate and develop alloys for use in high temperature applications;
• recover or recycle valuable materials from wastes;
• improve material production by melting or smelting;
• develop processes for efficient carbon management including the sequester of greenhouse gas emissions;
• improve efficiencies of high temperature melting or smelting systems; and
• improve power plant efficiency, and reduce power plant emissions.

The multi-disciplined Materials Science staff includes materials engineers, metallurgists, ceramists, geologists, chemists, chemical engineers, and mechanical engineers.

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