Materials Science and Engineering (MSE) is a focus area of the National Energy Technology Laboratory’s Office of Research and Development (ORD). ORD’s other focus areas are Computational and Basic Sciences, Energy System Dynamics, and Geological and Environmental Sciences. Scientists and engineers in ORD conduct research at NETL’s advanced research facilities in Morgantown, WV; Pittsburgh, PA; and Albany, OR, and at various offsite locations. 

MSE researchers develop materials and strategies that promote advanced energy conversion technologies, using computational and experimental approaches ranging from fundamental science through pilot-scale evaluation.  Much of the research focuses on the development and testing of new or improved structural and functional materials for the aggressive environments of the next generation of power plants.

Core Competencies
The multi-disciplined MSE staff—materials engineers, metallurgists, ceramic engineers, geologists, chemists, chemical engineers, and mechanical engineers—work closely with industry, academia, and other governmental organizations in the areas of advanced combustion, advanced gasification, fuel cells, CO₂ utilization, turbines (base materials and coatings), catalysis and nano-materials, batteries, membranes (H₂, CO₂, O₂ selective) and carbon-capture solvents and sorbents. MSE’s strong relationships with utilities and private industry allow it to assess gaps and identify limitations in today’s technologies and determine current and future materials needs. Core competencies include—

• Discovery and Design: Fundamental computational and experimental approaches to discover and rationally design robust structural and functional materials.
• Synthesis and Processing: Cost-effective and efficient synthesis and processing of materials at scales relevant for deployment, developing new approaches where appropriate.
• Characterization: Physical, mechanical, chemical, electrical, magnetic and optical properties of materials are characterized under realistic environments using both conventional ex-situ and novel rapid-response in-situ approaches.

Capabilities
Researchers at MSE synthesize novel structural and functional materials using a variety of preparation methodologies and thermal treatment methods. They can fabricate metal, ceramic, polymer, and composite materials at scales from proof-of-concept through bench scale and rapidly characterize materials and develop libraries detailing chemical and mechanical properties. Advanced capabilities allow them to melt, cast, forge, and heat-treat materials for a variety of industrial uses, and assess corrosion, erosion, creep, and wear in severe environments matching those found in advanced energy conversion processes.

Key Facilities

• Membrane Synthesis—Techniques for the fabrication of metal, ceramic polymer and composite membranes ranging from proof-of-concept through bench scale.
• Membrane Separation Units—Versatile test systems with online gas analysis are used to evaluate the permeability and selectivity of separation membranes at conditions consistent with coal conversion processes—temperatures up to 1000 °C and pressures up to 7 MPa—with the capability to add a variety of custom-blended, contaminant-laden gases.
• Solid Oxide Fuel Cell Test Facility—Test stands are used to evaluate the performance of fuel cell materials at scales ranging from single cells to small stacks.
• Chromatography—Gas chromatography capabilities include TCD, FID, AED, MS, and SCD detectors; liquid chromatography detectors include UV-Vis and MS-TOF.
• Catalysis Reaction Units—A variety of tubular and tank reactor systems are used to evaluate the kinetic properties and the deactivation trends and performance of thermo-, photo-, electro- and bio-catalyst systems. The reactor systems can operate at temperatures and pressures up to 1,200 °C and 7 MPa, respectively, with the capability of custom gas feeds and online gas analysis.
• Materials Processing—Advanced capabilities for melting, casting, forging, rolling and heat treating materials over wide scales for a variety of industrial uses.
• Materials Performance Evaluation—Facilities for evaluating the corrosion and oxidation of materials include the NETL Severe Environment Corrosion Erosion Facility (SECERF), which is a modular laboratory for safely exposing materials to temperatures up to 1600 °C, in appropriate mixtures of gases.  The unique dual atmosphere module of the SECERF has allowed MSE researchers to investigate the performance of advanced solid-oxide fuel cell interconnect alloys exposed simultaneously to anode and cathode environments. The SECERF also allows the study of the synergistic effect of wear and hot-corrosion, and has been used, for example, to study the effect of impingement of ash particles on boiler alloys and on wear of nozzles. The mechanical testing laboratory includes equipment for evaluating tensile, fatigue, and creep behavior of materials.
• Analytical Characterization—MSE laboratories are equipped with state-of-the-art equipment, including scanning electron microscopy, x-ray diffraction, transmission electron microscopy, low-energy ion-scattering, x-ray photoelectron spectroscopy, Auger election spectroscopy, and scanning tunneling microscopy.

Recent Achievements

• NETL’s MSE group developed a chrome oxide refractory material that can withstand the intense heat and corrosive environment of slagging gasifiers. The new refractory material resists spalling (the chipping or flaking of refractory material from an exposed face), resulting in a refractory with a longer service life.
• Researchers synthesized and characterized a new visible-light-activated catalyst that has the potential to enable conversion of CO₂ into valuable commodities.
• The MSE group developed a cerium oxide coating that can be applied to a variety of materials to retard corrosion in oxidizing environments. This approach, which received a 2010 R&D 100 award, increases efficiency in energy production and conserves resources such as coal and petroleum while protecting our environment.
• MSE’s researchers, in cooperation with International Titanium Products, developed a 2007 R&D 100 award-winning, low-temperature, low-pressure continuous process to produce titanium and titanium alloy powders at a substantially reduced cost.
• In cooperation with the U.S. Army Tank and Automotive Command, researchers developed methods for casting steel and titanium armor and vehicle hatch covers that are lighter, less expensive, and more effective than the previously used armor. NETL scientists have subsequently taught the manufacturers of the Army vehicles how to use the new technology.
• Using thermodynamic modeling, MSE researchers identified three new ferritic/martenistic compositions that could out-perform the state-of-the art tempered martensitic ferritic alloys currently in service at temperatures up to 620°C. The goal for the newly developed NETL compositions is to extend the temperature capability of this class of alloy to 650°C for service in ultra-supercritical coal-fired power plants that operate with greater efficiency, smaller carbon footprint, and lower cost than today's plants. The researchers also showed that addition of small amounts of light rare-earth elements can increase the ductility and creep resistance of refractory metal alloys.
• Subsequent laboratory tests of iron alloys with 22% chromium showed that they benefited from the addition of lanthanum and cerium because it reduced the size of metal oxide ridges and slowed the transport of scale-forming elements to the surface.

Doing Business with Us
NETL, the research arm of the U.S. Department of Energy’s Office of Fossil Energy, is advancing cost-effec­tive and environmentally sound technologies to meet the nation’s energy challenges. The Laboratory develops technologies and processes that answer pressing energy issues and provides our Nation’s policymakers with the scientific infor­mation they need to set sound energy policy.

NETL welcomes opportunities to work with academia and the private sectors to develop and commercialize energy and environmental technologies. We frequently use Cooperative Research and Development Agreements (CRADAs) with the private sector. We also enter into license agreements for applying our inventions, and we make our laboratories and scientists in available for work-for- or work-with-others arrangements.

Advanced Materials Brochure [PDF-6.18MB]

• Focus Area Leader (acting): Bryan Morreale, (412) 386-5929
• Director, Materials Performance Division: David Alman, (541) 967-5885
• Director: Process Development Division: Cathy Summers, (541) 967-5844