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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1994

Anomalous HNO3/NO(x) ratio of remote tropospheric air: Conversion of nitric acid to formic acid and NO(x)?

The N oxidation ratio, (HNO3)/(NO(x)), in the free troposphere is measured at approx. 1 to 9 (averaging approx. 5), consistently lower than the values of 15-100 which known theory suggests to be reached rapidly. This discrepancy casts doubt on current models' abilities to predict effects of NO sources on remote (NO), and so also (O3) and (OH). HNO3-to-NO(x) recycling processes involving HCHO in solution are appealing explanations for the ratio. Known chemical theory are illustrated using a Lagrangian box model of the mid-troposphere which simulates characteristic episodes form NO(x) input to HNO3 washout. Ratio and budget constraint equations for No(y) can usefully restrict conceivable explanations of missing chemistry of fast nitrogen cycling; most explanations could be called 'fast-cycles' or 're-NO(x)-ification.' These equations also show how current global models may suggest spuriously good N oxidation ratios and errors in OH. Aerosol or cloud droplets reactions with HCHO may produce (a) formic acid (which needs an appropriate source) and NO(x), or alternatively, (b) hydroxymethyl nitrate (or methyl dinitrate), which might supply a large, variable amount of 'missing NO(y) not currently measurable except by NO(y) instruments.

Chatfield, Robert B.↗

DOE OSTI2019

Manufacture of Wear-Resistant Cast-Iron Grinding Balls without Shrinkage Defects

A manufacturing technology has been developed for wear-resistant cast-iron grinding balls without shrinkage defects. In this method, the balls are cast in single-use sand–clay molds. A new approach to designing the casting system is developed. By numerical modeling, the time dependence of solidification is derived. As a trial, grinding balls are produced by the proposed technology.

42 ENGINEERING↗

DOE OSTI2020

Model-based Reconstruction for Single Particle Cryo-Electron Microscopy

Single particle cryo-electron microscopy is a vital tool for 3D characterization of protein structures. A typical workflow involves acquiring projection images of a collection of randomly oriented particles, picking and classifying individual particle projections by orientation, and finally using the individual particle projections to reconstruct a 3D map of the electron density profile. The reconstruction is challenging because of the low signal-to-noise ratio of the data, the unknown orientation of the particles, and the sparsity of data especially when dealing with flexible proteins where there may not be sufficient data corresponding to each class to obtain an accurate reconstruction using standard algorithms. In this paper we present a model-based image reconstruction technique that uses a regularized cost function to reconstruct the 3D density map by assuming known orientations for the particles. Our method casts the reconstruction as minimizing a cost function involving a novel forward model term that accounts for the contrast transfer function of the microscope, the orientation of the particles and the center of rotation offsets. We combine the forward model term with a regularizer that enforces desirable properties in the volume to be reconstructed. Using simulated data, we demonstrate how our method can significantly improve upon the typically used approach.

Venkatakrishnan, Singanallur↗

DOE OSTI2018

Carbide Particle Redistribution in U10Mo Alloy during Hot Rolling Process

The influence of initial carbide particle distribution features on the evolution of particle and stringer distribution within U10Mo alloy during hot rolling was investigated in this study. This work will provide guidance to casting optimization work and identify actionable process changes to eliminate the surface features directly attributed to carbides. Various synthetic microstructure-based finite-element (FE) models were generated with consideration of different parameters (i.e., particle shape, particle volume fraction and particle distribution). Plane-strain compression loading was employed in the FE models to simulate hot rolling to 40% and 80% reductions. Stringer statistics analyses and two-point correlation functions were then performed with the simulated hot-rolling results. The results from stringer analyses show that stringer volume fraction substantially increases with increased rolling reduction for microstructure with particles distributed along grain boundaries, and that microstructures with elliptical particles may have slightly higher stringer volume fractions than those with circular particles. The results also show that the maximum stringer length can increase substantially with increased rolling reduction for microstructures with elliptical particles along grain boundaries, and that the microstructures with higher-aspect-ratio elliptical particles may have higher stringer volume fraction and higher maximum stringer length. Near-surface numbers of particles and particle volume fractions also increase with increased rolling reduction. The results from application of the two-point correlation function show that the particle shape (i.e., circular or elliptical) may not have significant influence on the overall shapes of the correlation curves, and that the correlation curves tend to show higher peaks at short distance and then gradually decrease for microstructures with higher particle volume fractions and particles distributed along grain boundaries.

36 MATERIALS SCIENCE↗

NASA NTRS1989

Comparison of two- and three-dimensional Navier-Stokes solutions with NASA experimental data for CAST-10 airfoil

The two-dimensional (2-D) and three-dimensional Navier-Stokes equations are solved for flow over a NAE CAST-10 airfoil model. Recently developed finite-volume codes that apply a multistage time stepping scheme in conjunction with steady state acceleration techniques are used to solve the equations. Two-dimensional results are shown for flow conditions uncorrected and corrected for wind tunnel wall interference effects. Predicted surface pressures from 3-D simulations are compared with those from 2-D calculations. The focus of the 3-D computations is the influence of the sidewall boundary layers. Topological features of the 3-D flow fields are indicated. Lift and drag results are compared with experimental measurements.

Swanson, R. Charles↗

DOE OSTI2020

Field-Scale Lysimeter Studies of Glass and Cementitious Waste Forms at the Hanford Site - 20392

The Hanford site Integrated Disposal Facility (IDF) will receive waste forms from vitrification activities at the Hanford Waste Treatment and Immobilization Plant (WTP). The waste form inventory to be disposed of at the IDF will consist of vitrified low-activity waste (LAW) in glass forms and solidified (or encapsulated) secondary wastes in cementitious forms. The IDF is a near-surface burial facility located near Hanford's Waste Treatment and Immobilization Plant in the 200 East Area of the site's Central Plateau. An extensive set of laboratory experimental data has been collected to support IDF performance assessment calculations of the eventual degradation of waste forms and mobility of contaminants. This paper describes the start of a field experiment to generate waste-form performance data on a larger scale (tens of centimeters), over a longer duration (five years or more), and under field conditions representative of the IDF. Results from this study are expected to improve model descriptions of contaminant mobility, reduce uncertainties about the representativeness of laboratory results in the IDF performance assessment, improve stakeholder confidence in the safe disposal of treated waste at the IDF, and facilitate the adoption of informed facility designs with the potential to reduce operational costs. A lysimeter test facility near Hanford's 200 West Area has been repurposed to carry out long-term assessments of waste forms buried in sediments excavated from the IDF. The waste forms are buried in large drainage lysimeters, open caissons that are two meters in diameter and three meters deep. Waste forms are buried in up to six locations in each lysimeter. Samplers collect pore water and drainage water beneath the waste forms and air from the pore space adjacent to waste forms. Sensors measure temperature, soil water content, soil water tension, and drainage flux. One lysimeter containing cementitious waste forms and one containing glass waste forms have been completed, along with a control lysimeter (without waste forms). The cementitious waste forms are Cast Stone grout formulations using a liquid secondary waste simulant and a generic Hanford high-salt simulant, as well as a hydrated lime-based grout formulation using a liquid secondary waste simulant. Technetium-99 and iodine-127 were added as tracers to monitor contaminant mobility. Glass waste forms were fabricated in two formulations (LAWA44 and ORLEC28), with rhenium and molybdenum tracers to monitor waste form degradation. The predicted performance of the waste forms in the lysimeters was modeled prior to installation to determine waste form size, tracer concentration/activity, and locations of sensors and samplers. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2022

Computational Design of a Simple Flyer Plate Launcher

The response of materials to shock loading is important to understand for a variety of applications. When shock physics emerged during and after WWII, direct explosive loading or explosively driven plate impact was the primary tool for these studies. Subsequent decades have seen the widespread use of large caliber guns for plate impact studies, laser-shock facilities and pulsed power facilities. INL currently lacks a gun suitable for plate impact or explosives casting and machining facilities; however, it does possess explosives use and handling capabilities. An option for performing plate impact experiments was needed, therefore continuum scale models were utilized to explore a few simple donor-acceptor explosive plane wave lens designs, one of which could be hand packed with plastic explosives to launch flyer plates. 2D simulations were performed to study different geometries in an effort to minimize the difference in shock arrival across the central portion of a small copper flyer plate. A shock wave arrival time difference under 50 ns across 50 percent of the center of the flyer was achieved with a few designs. This work summarizes the computational models and results.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Strontium Effects on the Formation of Iron-Intermetallic Phases in Secondary Al–9Si–0.6Fe Alloys

The presence and morphology of Fe-containing intermetallic phases affect the mechanical properties of aluminum alloys, especially in secondary Al–Si-based cast alloys. Although strontium (Sr) addition of 50 to 500 ppm is known to refine the needle-type eutectic silicon structure, the influence of Sr on the formation of Fe-intermetallic phases remains unclear. The present work investigates the combined additions of Sr and Mn to Al–9Si–0.6Fe–0.35Mg (All compositions are in wt pct except otherwise stated.) alloys on the formation of Fe-intermetallic phases at different solidification rates from ~ 1.5 to ~ 60 °C/s. Long and branched-type AlFeSi phase with size ranging from 50 to 120 µm are more common when solidified at the rate of 1.5 °C/s regardless of Sr and Mn additions. However, at the fast solidification rate of 60 °C/s, a 60 ppm Sr addition significantly reduced the average length of needle-shaped AlFeSi phase to less than 3 to 5 µm. Thermodynamic simulations have been performed using CALculation of PHAse Diagrams (CALPHAD) models to predict the formation of various phases and their possible interactions during solidification. The results indicated that the combination of a high solidification rate and about 60 ppm of Sr is beneficial to refining the δ-Al 3 FeSi 2 phase in Al–Si–Mg alloys containing 0.6 pctFe. As a result, this unexpected finding of Fe-intermetallic refinement by low Sr addition (~60 ppm) provides an important guide in designing secondary alloys for sustainable casting applications.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Bridging Current Indirect and Future Direct Estimates of Convective Mass Flux Toward Quantifying the Role of Convective Cores on Anvil Area Time Tendencies

Anvil cloud spatial extent is strongly driven by convective mass flux. However, the lack of convective mass flux observations precludes global analyses of the functional relationship between anvil cloud area growth tendencies and convective areal coverage and vertical mass flux. Partly informed by analyses of a hierarchy of WRF mesoscale convective system (MCS) simulations, in this presentation, we discuss new work on estimating convective mass flux by way of an approach that casts the problem of quantifying convective mass flux into terms related to diabatic heating vertical structure, convective area and tropospheric stability. We demonstrate the usefulness of this approach at the MCS spatial scale via development of a simple, robust model that analytically connects system-scale convective mass flux and anvil cloud area growth rates. We show that the model predicts anvil area size changes in agreement with those observed in a global convective system tracking database (TOOCAN). An additional advantage of this approach for estimating convective mass flux is that it bridges future satellite mission plans for directly observing convective mass flux (e.g., AOS) with longer-record observations made by TRMM, GPM and satellite sounder mission data (the latter used for estimating stability) that, when combined, can be used for inferring convective mass fluxes at the MCS spatial scale spanning slowly changing, diverse environments. An evaluation and bridging of both direct and indirect approaches supports convective process analyses varying over longer time periods in this “era of convection.”

convective mass flux↗

NASA NTRSDate not supplied

Bridging current indirect and future direct estimates of convective mass flux toward quantifying the role of convective cores on anvil area time tendencies

convective mass flux↗

DOE OSTI2017

Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Physical and optical properties of the International Simple Glass

Abstract Radioactive waste immobilization is a means to limit the release of radionuclides from various waste streams into the environment over a timescale of hundreds to many thousands of years. Incorporation of radionuclide-containing wastes into borosilicate glass during vitrification is one potential route to accomplish such immobilization. To facilitate comparisons and assessments of reproducibility across experiments and laboratories, a six-component borosilicate glass (Si, B, Na, Al, Ca, Zr) known as the International Simple Glass (ISG) was developed by international consensus as a compromise between simplicity and similarity to waste glasses. Focusing on a single glass composition with a multi-pronged approach utilizing state-of-the-art, multi-scale experimental and theoretical tools provides a common database that can be used to assess relative importance of mechanisms and models. Here we present physical property data (both published and previously unpublished) on a single batch of ISG, which was cast into individual ingots that were distributed to the collaborators. Properties from the atomic scale to the macroscale, including composition and elemental impurities, phase purity, density, thermal properties, mechanical properties, optical and vibrational properties, and the results of molecular dynamics simulations are presented. In addition, information on the surface composition and morphology after polishing is included. Although the existing literature on the alteration of ISG is not extensively reviewed here, the results of well-controlled static alteration experiments are presented here as a point of reference for other performance investigations.

36 MATERIALS SCIENCE↗

DOE OSTI2018

On the Solidification and Structure Formation during Casting of Large Inserts in Ferritic Nodular Cast Iron

The graphite nodule count and size distributions for boiling water reactor (BWR) and pressurized water reactor (PWR) inserts were investigated by taking samples at heights of 2160 and 1150 mm, respectively. In each cross section, two locations were taken into consideration for both the microstructural and solidification modeling. The numerical solidification modeling was performed in a two-dimensional model by considering the nucleation and growth in eutectic ductile cast iron. The microstructural results reveal that the nodule size and count distribution along the cross sections are different in each location for both inserts. Finer graphite nodules appear in the thinner sections and close to the mold walls. The coarser nodules are distributed mostly in the last solidified location. The simulation result indicates that the finer nodules are related to a higher cooling rate and a lower degree of microsegregation, whereas the coarser nodules are related to a lower cooling rate and a higher degree of microsegregation. The solidification time interval and the last solidifying locations in the BWR and PWR are also different.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Multifrequency eddy-current detection of fast transient thermal signatures for in situ monitoring applications

Eddy-current (EC) nondestructive evaluation has a long history of use in a variety of ex situ defect monitoring applications because of its exquisite sensitivity to local material variations. Due to the relationship between a material's conductivity and its temperature, EC methods have also been used to investigate quasistatic, long-range temperature variations in casting applications. However, these techniques remain underutilized for the measurement of rapidly varying, spatially nonuniform temperature distributions. In this work, we construct a model system capable of generating repeatable temperature transients in steel plates and measure real-time eddy-current signals with millisecond time resolution and spatial resolution of the order of 1 mm. Using a combination of Multiphysics simulations, fast thermal imaging, and time-resolved holographic interferometry, we tease apart contributions to the eddy-current signals arising from temperature variations and transient plate deformation. Finally, we perform a systematic study in which we vary the plate thickness and the eddy-current excitation frequency to demonstrate that eddy-current techniques can provide information about a three-dimensional, time-varying, subsurface thermal distribution, which is inaccessible to the traditional thermal imaging techniques.

Rosenberg, Ethan R. [Lawrence Livermore National L↗

DOE OSTI2021

Creation of a prototype biomimetic fish to better understand impact trauma caused by hydropower turbine blade strikes

Biomimetic model organisms could be useful surrogates for live animals in many applications if the models have sufficient biofidelity. One such application is for use in field and laboratory tests of fish mortality associated with passage through hydropower turbines. Laboratory trials suggest that blade strikes are especially injurious and often causes mortality when fish are struck by thinner blades moving at higher velocities. Dose-response relationships have been created from these data, but the exact relationship between fish mortality and the actual forces enacted on fish during simulated blade strike testing remains unknown. Here, we describe the methods used to create a prototype biomimetic model fish composed of ballistic gelatin and covered with a surrogate skin to better approximate the biomechanical properties of a fish body. Frozen fish were scanned with high-fidelity laser scanners, and a 3D-printed, reusable mold was created from which to cast our gelatin model. Computed tomography scan data, imaged directly or taken from online data repositories, were also successfully used to create CAD models for use in additive manufacturing of molds. One 3-axis accelerometer was embedded into the gelatin to compare accelerometer data to dose-response data from previous laboratory research on live fish. The resulting model ( i.e. , Gelfish) had a statistically indistinguishable tissue durometer to that of real fish tissue and preliminary blade strike impact testing suggested its overall flexibility was similar to that of live fish. Gelfish was designed with biofidelity as its guiding principle and our results suggest initial experimentation was successful. Future research will include replication of initial Gelfish test results, quantitative measurement of model flexibility relative to real fish, and inclusion of surrogate skeletal structures to enhance biofidelity. Use of more sophisticated sensors would also better quantify the physical forces of blade strike impact and help determine how said forces correlate with rates of mortality observed during tests on live fish.

36 MATERIALS SCIENCE↗

NASA NTRS2012

Plasma Wake Simulations and Object Charging in a Shadowed Lunar Crater During a Solar Storm

Within a permanently shadowed lunar crater the horizontal flow of solar wind is obstructed by upstream topography, forming a plasma wake that electrostatically diverts ions toward the crater floor and generates a surface potential that can reach kilovolts. In the present work kinetic plasma simulations are employed to investigate the morphology of a lunar crater wake during passage of a solar storm. Results are cast in terms of leading dimensionless ratios including the ion Mach number, ratio of crater depth to plasma Debye length, peak secondary electron yield, and electron temperature vs. electron impact energy at peak secondary yield. This small set of ratios allows generalization to a much wider range of scenarios. The kinetic simulation results are fed forward into an equivalent-circuit model of a roving astronaut. In very low-plasma-current environments triboelectric charging of the astronaut suit becomes effectively perpetual, representing a critical engineering concern for roving within shadowed lunar regions. Finally, simulated ion fluxes are used to explore sputtering and implantation processes within an idealized crater. It is suggested that the physics of plasma mini-wakes formed in the vicinity of permanently shadowed topography may play a critical role in modulating the enigmatic spatial distribution of volatiles at the lunar poles.

Zimmerman, Michael I.↗

DOE OSTI2021

Shrinkage-induced deformations and creep of structural concrete: 1-year measurements and numerical prediction

Highlights: • Extensive experimental study on drying shrinkage, creep and microcracking of concrete • All specimens prepared from a single batch of ordinary-strength structural concrete • 1st year of measurements of (not only) non-uniformly drying beams with span up to 3-m • The database is downloadable from free-to-use research data repository • Modified MPS model for concrete creep used in blind prediction of all experiments The material models for creep and shrinkage operating on the material point level in FEM are usually intended for challenging complex applications and structures, where the average cross-sectional approach does not suffice. The identification of the growing number of material parameters induced by increasing model capabilities relies on very specific and narrow-oriented yet interconnected experiments which are scarce. The presented comprehensive experiments aim to provide a clearer image of the complicated interaction among the basic phenomena: drying, shrinkage, creep, and microcracking. The cornerstone of this ongoing research is a unique set of 30 partially-sealed unreinforced concrete beams with span 1.75–3.0 m subjected to drying. To minimize material variation, all specimens in this study were cast from a single batch of ordinary strength structural concrete with slag-blended binder. The resulting experimental database will be suitable both for validation and development of the constitutive models.

36 MATERIALS SCIENCE↗

NASA NTRS1985

Constitutive modeling for isotropic materials

The first year of progress on a NASA-Lewis contract with the General Electric Co is documented. The purpose of this contract (NAS3-23927) is to develop and evaluate unified constitutive equations for applications to hot-path components of aircraft gas turbine engines such as high pressure turbine blades and vanes. To accomplish this goal, uniaxial, notched, and multiaxial specimens made of conventionally cast Rene 80 are being tested under conditions that simulate engine operating conditions. To reduce the raw data, automated data reduction techniques are being developed that produce computer files containing the information needed to analyze proposed constitutive theories. Described are the analytical methods being developed to determine the parameters for these nonlinear unified theories by using the reduced data files. In another activity, a dedicated finite-element computer code is being developed to use unified theories in the structural analysis of hot-section components. This code was extensively verified for one such theory by successfully predicting the strain histories measured experimentally at the notch root of complex specimens taken from complex laboratory specimens.

Ramaswamy, V. G.↗