INL RESEARCH & DEVELOPMENT

Coatings

Corrosion

Fracture and Mechanical Testing

High Temperature Mechanical 

Properties

Hydrogen Production and Storage 

Materials

Hydrogen Separation Materials

Irradiation

Materials Validation

Microstructure and Physical Properties

Modeling

Neutron Radiography

Nondestructive Evaluation

Post-irradiation Examination

Synthesis and Processing of 

Novel Materials

Welding and Joining

X-Ray Radiography

Capabilities/Facilities

Conventional laboratory scale powder handling, hot-pressing and sintering, and thermal 

spray capability, and solid 

state combustion synthesis. 

Large scale high temperature 

vacuum induction furnace 

(85° liters and 1700°C) capable of handling uranium; remotely-contained hot-isostatic 

press capable of processing 

irradiated materials, fission 

products, and actinides (U, 

Pu, Am, Np, Cm, Th); and 

sintering furnace in-cell. 

Cold-wall induction melter 

for rapid melting of materials, 

and several glovebox furnaces 

and arc melters that are capable of handling U, Pu, and 

minor actinides. 

Synthesis and Processing of 

Novel Materials

Continued on next page

Dissimilar materials, e.g., metals and ceramics, cannot be joined. But functionally graded materials, such 

as this Ni-Al2O3 sample, have the best properties of both base materials.

Materials

Neutron-absorbing materials, 

functional gradient materials, 

fuel cell materials, steel, zirconium, uranium, plutonium, 

minor actinides, ceramics, nanoscale materials, and fission 

products, and intermetallics 

(NiAl, Ni3Al, TiAl).

Scientific/Engineering 

Issues

Synthesis of novel functional 

materials (e.g., controlled 

conductivity, graded elastic 

modulus); sample preparation for microstructural, 

mechanical, and properties 

characterization of radioactive 

materials; plasma synthesis 

of nano-sized Ti and complex 

ceramics; plasma synthesis 

of hydrides; near-net and 

net-shape spray forming of 

engineering alloys.

Staff

K.J. Bateman, K. Marsden, 

W.E. Windes, P.A. Lessing, R.E. Mizia, P.C. Kong, 

B.A. Detering, L.D. Zuck, 

K.M. McHugh, G.A. Moore, 

J. Stuart, I. Glagolenko, 

J.R. Kennedy, K. Carney, 

C. Clark, M.K. Meyer.

Recent Projects

• Neutron absorber materials 

for Yucca Mountain 

• Fabrication and characterization of dual-phase 

MgO-based ceramics for 

use as an inert fuel matrix

• Equipment used to support several ongoing 

projects, including fabrication of uranium-bearing 

waste forms, RTG power 

sources, actinide-bearing 

alloys, and ceramic waste 

forms

100% Al

2O3

100% Al

2O3

100% Ni

Ni - Al2O3 composite structure

Bulk sample

Tensile specimen
INL RESEARCH & DEVELOPMENT

05-GA50193-43

For more information

INL is a U.S. Department of Energy 

national laboratory operated by 

Battelle Energy Alliance

Richard N. Wright, Ph.D.

(208) 526-6127

Richard.Wright@inl.gov

Douglas C. Crawford, Ph.D.

(208) 533-7456

Douglas.Crawford@inl.gov

www.inl.gov/envenergyscience/materials

Continued from front

• “Nanoscale Metal Hydride 

Synthesis and Characterization,” Defense Threat 

Reduction Agency, Advanced Energetics Program. 

• Solid oxide fuel cell 

(SOFC) development.

• Electrophoretic deposition 

of continuous metal-ceramic graded structures.

• DTRA Advanced Energetcs Program, “Nanoscale 

Metal Hydride Synthesis 

and Characterization.”

• Fabrication and analysis of 

rapidly solidified aluminum alloy strip. 

• Development of advanced 

tooling alloys and the 

fabrication of DTRA 

Advanced molds and dies 

from these alloys. 

• Processing and testing 

of metal-encapsulated 

ceramic armor systems. 

Collaborations

• Westinghouse and Pennsylvania State University, 

corrosion of zircaloy cladding

• Texas A&M University, 

development of corrosion 

resistant, high thermal 

conductivity, inert fuel 

matrices

• University of CaliforniaDavis, Colorado School 

of Mines, Alcoa, Pechiney 

Rolled Products, Inductotherm Corp., and Metals 

Technology Inc.: “Spray 

Rolling Aluminum Strip.”

• University of CaliforniaDavis, RSP Tooling LLC, 

Glass Manufacturing 

Industry Council, and General Aluminum Manufacturing, Inc.: “Development 

and Demonstration of 

Advanced Tooling Alloys 

For Molds and Dies.”

• Tank Automotive Armament Command (TACOM): “Encapsulated 

Ceramic Armor Systems 

Processed via Spray Forming.” 

• P. I. Peter Kong - PPG 

Industries CRADA: “Synthesis of Nano Particles in 

a Modular Arc Reactor”

• P. I. Peter Kong - PPG/

INL DRAPA Project: 

“Plasma Synthesis of Nano 

Boron Carbide Powder.”

Publications

“Dual Phase Magnesia-Zirconia Ceramics with Strength 

Retention at Elevated Temperature,” T.C. Yuan, G.V. 

Srinivasan, J.F. Jue and A.V. 

Virkar, Journal of Materials Science, Vol. 24, p. 3855, 

1989.

“Fabrication, Microstructural 

Characterization and Mechanical Properties of Polycrystalline tʼ-Zirconia,” J.F. Jue and 

A.V. Virkar, Journal of the 

American Ceramic Society, 

Vol. 73, p. 3650, 1990.

“Synthesis and Characterization of Gadolinium Phosphate Neutron Absorber,” 

P.A. Lessing and A.W. Erickson, Journal of the European 

Ceramic Society, Vol. 23, p. 

3049, 2003.

“Electrophoretic Deposition Applied to Thick 

Metal-Ceramic Coatings,” 

W.E. Windes, J. Zimmerman, 

and I.E. Reimanis, Surface 

and Coatings Technology,

Vol. 157, p. 267, 2002.

“Syntesis of Nanocrystalline 

NASICON-type Thin Film 

Ceramics”, P.A. Lessing and 

G. Huestis, accepted by the 

Journal of Ceramic ProcessNiAl

NiAl

Anode

Electrolyte

Cathode

LSC

Exploded schematic view 

showing layers of a single cell 

SOFC.

Illustration of bipolar plate 

configuration for solid oxide fuel 

cell (SOFC).

ing Research.

“Plasma Spray Coatings for 

SOFC”, W.E. Windes and 

P.A. Lessing, 2002 Fuel Cell 

Seminar Abstracts, 471-474 

(2002); Courtesy Associates, 

2025 M. Street. N.W., Suite 

800, Wash., D.C. 20036.

“Fabrication Methods of a 

Leaky SOFCO Design”, 

W.E. Windes and P.A. Lessing, Eighth International 

Symposium of Solid Oxide 

Fuel Cells (SOFC VIII), 203rd

meeting of the Electrochemical Society, Paris, France, 

April 27-May 2, 2003. (Peer 

reviewed.)

“Spray Rolling Aluminum Alloy Strip,” Kevin M. McHugh, J.P. Delplanque, S.B. Johnson, E.J. 

Lavernia, Y. Zhou and Y. Lin, 

Mater. Sci. Eng. A 383(1), 96 

(2004).

 “The Selection of the Spray 

Deposition Rate During the 

Spray Rolling Process,” 

Y.J. Lin, K.M. McHugh, 

Y. Zhou, and E.J. Lavernia, 

Metall. Mater. Trans. A 35, 

3595 (2004).

“The Transient to SteadyState Transition During the 

Spray Rolling Process,” 

Y.J. Lin, K.M. McHugh, 

Y. Zhou, and E.J. Lavernia, 

Metall. Mater. Trans. A 35, 

3633 (2004).