Hot hydrogen testing of direct current sintered NbC and (ZrNbW)C for nuclear thermal propulsion

•NbC and (Zr0.4Nb0.4W0.2)C were consolidated by direct current sintering,•Samples were exposed to hydrogen flow for up to 3 h and 2500 K.•The mass loss rate for NbC in flowing hydrogen was about 1 mg/m2.•Mass loss rates were compared between hydrogen and argon exposures.•Residual oxygen was preferentially removed upon hydrogen exposure. Refractory carbides are promising materials for use in nuclear thermal propulsion, either as the primary material in nuclear fuel elements or as protective coatings. In particular, NbC and ZrC have high melting points, relatively low vapor pressures at elevated temperatures, and low thermal neutron cross sections. In this study, NbC and (Zr0.4Nb0.4W0.2)C were fully consolidated by direct current sintering, and relative densities of 98% were achieved. The samples were characterized by scanning electron microscopy and X-ray diffraction before and after hydrogen testing. The samples were exposed to hot flowing hydrogen gas at a pressure of 1 atm and a flow rate of 8 SLPM, at temperatures up to 2500 K, and for durations up to 3 h. The mass loss rate (MLR) of NbC decreased with increasing exposure, before reaching a steady state value of about 1 mg/m2s. For (ZrNbW)C, a comparison was made by exposing samples to either hot flowing hydrogen or argon gas. The mass loss rates decreased with increasing exposure to either gas, but the final steady-state MLR was one to two orders of magnitude greater for those samples exposed to hydrogen. As evidenced by X-ray data, small amounts of residual oxygen in the (ZrNbW)C samples were preferentially removed upon hydrogen exposure.