The formation of magnesium chloride-hydroxide salts (magnesium hydroxychlorides) has implications for many geochemical processes and technical applications. For this reason, a thermodynamic database for evaluating the Mg(OH)2–MgCl2–H2O ternary system from 0 °C–120 °C has been developed based on extensive experimental solubility data. Internally consistent sets of standard thermodynamic parameters (ΔGf°, ΔHf°, S°, and CP) were derived for several solid phases: 3 Mg(OH)2:MgCl2:8H2O, 9 Mg(OH)2:MgCl2:4H2O, 2 Mg(OH)2:MgCl2:4H2O, 2 Mg(OH)2:MgCl2: 2H2O(s), brucite (Mg(OH)2), bischofite (MgCl2:6H2O), and MgCl2:4H2O. First, estimated values for the thermodynamic parameters were derived using a component addition method. These parameters were combined with standard thermodynamic data for Mg2+(aq) consistent with CODATA (Cox et al., 1989) to generate temperature-dependent Gibbs energies for the dissolution reactions of the solid phases. These data, in combination with values for MgOH+(aq) updated to be consistent with Mg2+-CODATA, were used to compute equilibrium constants and incorporated into a Pitzer thermodynamic database for concentrated electrolyte solutions. Phase solubility diagrams were constructed as a function of temperature and magnesium chloride concentration for comparisons with available experimental data. To improve the fits to the experimental data, reaction equilibrium constants for the Mg-bearing mineral phases, the binary Pitzer parameters for the MgOH+ — Cl− interaction, and the temperature-dependent coefficients for those Pitzer parameters were constrained by experimental phase boundaries and to match phase solubilities. These parameter adjustments resulted in an updated set of standard thermodynamic data and associated temperature-dependent functions. The resulting database has direct applications to investigations of magnesia cement formation and leaching, chemical barrier interactions related to disposition of heat-generating nuclear waste, and evaluation of magnesium-rich salt and brine stabilities at elevated temperatures.
Stress corrosion cracking behavior of stainless steel 304 L was investigated in full immersion, evaporated artificial sea salt brines (ASW) at 55 °C. It was observed that brines representative of thermodynamically stable brines at lower relative humidity (40% RH, MgCl2-dominant) had a faster crack growth rate than high relative humidity brines (76% RH, NaCl-dominant). Observed crack growth rates (da/dt) under constant stress intensity (K) conditions were determined to be independent of transitioning procedure (rising K or decreasing frequency) regardless of solutions investigated for the orientation presented. Further, positive strain rates had little to no impact on the observed da/dt. The observed behavior suggests an anodic dissolution enhanced hydrogen embrittlement mechanism for SS304L in concentrated ASW environments at 55 °C. Additional explorations further examined environmental influences on da/dt. Nitrate additions to 40% ASW at 55 °C solutions were shown to decrease measured da/dt and further additions stopped measurable crack growth. After sufficient nitrate had been added to fully stifle crack growth, a temperature increase to 75 °C induced cracking again, and a subsequent decrease to 55 °C once again stopped da/dt. These tests demonstrate the importance of ascertaining both brine-specific chemical and dynamic environmental influences on da/dt.
Work evaluating spent nuclear fuel (SNF) dry storage canister surface environments and canister corrosion progressed significantly in FY23, with the goal of developing a scientific understanding of the processes controlling initiation and growth of stress corrosion cracking (SCC) cracks in stainless steel canisters in relevant storage environments. The results of the work performed at Sandia National Laboratories (SNL) will guide future work and will contribute to the development of better tools for predicting potential canister penetration by SCC.
This report summarizes the activities performed by Sandia National Laboratories in FY23 to identify and test coating materials for the prevention, mitigation, and/or repair of potential chloride-induced stress corrosion cracking in spent nuclear fuel dry storage canisters. This work continues efforts by Sandia National Laboratories that are summarized in previous reports from FY20 through FY22 on the same topic. In FY23, Sandia National Laboratories, in collaboration with five industry partners through a memorandum of understanding, evaluated the physical, mechanical, and corrosion-resistance properties of eight different coating systems. The evaluation included thermal and radiation environments relevant to various time periods of storage for spent nuclear fuel canisters. The coating systems include polymeric (polyetherketoneketone, modified polyimide/polyurea, modified phenolic resin, epoxy), organic/inorganic ceramic hybrids (silane-based polyurethane hybrid and a quasi-ceramic sol-gel polyurethane hybrid), and coatings utilizing a Zn-rich primer applied to stainless steel coupons. The results and implications of these tests are summarized in this report. These analyses will be used to identify the most effective coatings for potential use on spent nuclear fuel dry storage canisters and to identify specific needs for further optimization of coating technologies for application on spent nuclear fuel canisters.
Measured salt compositions in dust collected over roughly the last decade from surfaces of in-service stainless-steel alloys at four locations around the United States are presented, along with the predicted brine compositions that would result from deliquescence of these salts. The salt compositions vary greatly from ASTM seawater and from laboratory salts (i.e., NaCl or MgCl2) commonly used on corrosion testing. The salts contained relatively high amounts of sulfates and nitrates, evolved to basic pH values, and exhibited deliquescence relative humidity values (RH) higher than seawater. Additionally, inert dust in components were quantified and considerations for laboratory testing are presented. The observed dust compositions are discussed in terms of the potential corrosion behavior and are compared to commonly used accelerated testing protocols. Finally, ambient weather conditions and their influence on diurnal fluctuations in temperature (T) and RH on heated metal surfaces are evaluated and a relevant diurnal cycle for laboratory testing a heated surface has been developed. Suggestions for future accelerated tests are proposed that include exploration of the effects of inert dust particles on atmospheric corrosion, chemistry considerations, and realistic diurnal fluctuations in T and RH. Understanding mechanisms in both realistic and accelerated environments will allow development of a corrosion factor (i.e., scaling factor) for the extrapolation of laboratory-scale test results to real world applications.
Pitting corrosion was evaluated on stainless steels 304H, 304, and 316L the surfaces of which had ASTM seawater printed on them as a function of surface roughness after exposure to an exemplar realistic atmospheric diurnal cycle for up to one year. Methods to evaluate pitting damage included optical imaging, scanning electron microscopy imaging, profilometry analysis, and polarization scans. The developed cyclic exposure environment did not significantly influence pitting morphology nor depth in comparison to prior static exposure environments. Cross-hatching was observed in a majority of pits for all material compositions with the roughest surface finish (#4 finish) and in all surface finishes for the 304H composition. Evidence is provided that cross-hatched pit morphologies are caused by slip bands produced during the grinding process for the #4 finish or by material processing. Additionally, micro-cracking was observed in pits formed on samples with the #4 surface finish and was greatly reduced or absent for pits formed on samples with smooth surface finishes. This suggests that both a low RH leading to an MgCl2-dominated environment and a rough surface containing significant residual stress are necessary for micro-cracking. Finally, the use of various characterization techniques and cross sectioning was employed to both qualitatively and quantitatively assess pitting damage across all SS compositions and surface finishes.