NETL Patents Advance High-Temperature, Nickel-Based Alloys for Power Generation, More

NETL's new patented nickel (Ni)-based alloy, its patented composition, method of manufacture and heat treatment will advance the reliability of next generation power generation and other applications while lowering operating costs.

This advancement in alloy development will also play an integral role in ensuring a supply of reliable, affordable material needed to produce substantially greater amounts of electricity and meet the demands of America's increasingly power-hungry, data-driven economy.

The Lab's NiCrMoNb (nickel-chromium-molybdenum-niobium) alloy possesses a unique combination of corrosion/oxidation resistance and elevated temperature mechanical properties and allows for improved durability over currently available alloys.

NETL's breakthrough in alloy development was achieved through the development of three patents.

• US 11,827,955 is the original patent issued and covers the composition of the alloy.
• US 12,264,383 is the divisional patent covering the heat treatments for the alloys, including homogenization heat treatment and aging heat treatment. Homogenization is a heat treatment process used in metal alloys to achieve a more uniform chemical composition by allowing alloying elements to redistribute evenly through diffusion. The process involves heating the alloy to a high temperature, close to its melting point and holding it there for a specific duration before slowly cooling it. This creates a more stable, consistent and workable internal structure, enhancing mechanical properties and preventing product failure from areas of extreme softness or brittleness.
• US 2025/0243564 is the newest patent application. It outlines NETL's heat treatment schedule for the materials and the need for high chemical homogeneity. This is a result of the homogenization heat treatment.

"Such robustness is necessary to meet the changing needs that contemporary alloys were never designed to meet," said Martin Detrois, a research scientist with NETL's Structural Materials Team. "Future power plant designs are expected to operate at higher temperatures to meet the increasing demand for affordable and reliable energy. These developments are crucial to the United States leading the world in energy development and innovation."

The advantages of NETL's NiCrMoNb alloy aren't limited to use in power plants.

"The same manufacturing principles behind the development of our NiCrMoNb alloy during the past four years can be applied to a host of other industries apart from coal-fired power plants," Detrois said.

"These include natural gas, aero engines, power generation systems using fluids, nuclear power plants and molten salt reactors. The variety of potential uses and the cost savings involved make NETL's NiCrMoNb alloy an attractive option to commercial users," Detrois said.

NETL is a U.S. Department of Energy (DOE) national laboratory dedicated to innovating and accelerating the nation's energy solutions in hydrocarbon, geothermal energy and critical minerals production. With research sites in Albany, Oregon; Morgantown, West Virginia; and Pittsburgh, Pennsylvania, NETL operates as one laboratory to create advanced energy technologies that support DOE's mission and enable affordable, reliable and secure energy to fuel human prosperity.