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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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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Evaluating methods to reduce duration of near-threshold fatigue crack growth rate measurements for low-alloy steels in hydrogen gas

Measurement of the near-threshold fatigue crack growth rate (da/dN) vs. stress-intensity factor range (∆K) relationship in hydrogen gas is essential for maximizing the calculated design fatigue life of high-pressure hydrogen storage vessels. However, such measurements are rarely performed, since the low cyclic loading frequencies applied in standard practice lead to prohibitively protracted test durations. The objective of this study was to demonstrate two means for reducing test durations when measuring near-threshold da/dN vs. ΔK relationships under decreasing ΔK for low-alloy pressure vessel steels in hydrogen gas: 1) imposing steeper K-gradients relative to the recommended limits in standards such as ASTM E647, and 2) increasing cyclic loading frequency relative to typical values applied during fatigue crack growth testing of low-alloy steels in hydrogen gas. Recognizing that steeper K-gradients could amplify loading-history effects, test methods employing this approach were designed to mitigate such effects by either maintaining constant K max or gradually increasing the K-gradient as the threshold was approached. Although the varying K-gradient method was vulnerable to loading-history effects in the form of plasticity-induced crack closure, particularly at lower stress ratio (R) and higher starting K max values, these effects could be compensated by applying the adjusted compliance ratio (ACR) method. Here, it was demonstrated that steeper K-gradients in concert with increased cyclic loading frequency reduced the duration of near-threshold fatigue crack growth tests in hydrogen gas by more than 99% relative to standard practices.

Fatigue threshold↗
DOE OSTI2024

Design by analysis rules for ASME Section III, Division 5, Class B components

The current rules for elevated temperature ASME Section III, Division 5, Class B components, other than piping, were basically adapted from the Design-by-Rule approach for Section VIII, Division 1 vessels. A goal of the proposed new rules is to explicitly account for the design life and cyclic service while recognizing the less-rigorous requirements commensurate with lesser safety consideration. Further goals are to maximize the use of modern computational technology, for example finite element analysis in conjunction with reference stress concepts, and to avoid the need for stress classification. This paper summarizes the work done to address these issues. A summary of the design-by-analysis for primary loads, strain limit evaluation, and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules and the experimental data obtained from a family of a simplified model test-based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Free-spray characteristics and spray-wall interactions of methanol on a gasoline direct injector under flash-boiling and non-flash-boiling conditions

Methanol is considered a promising alternative fuel for internal combustion engines (ICEs) due to its high-octane number, fast laminar flame speed, and elevated latent heat of vaporization, all of which support higher compression ratios and improved thermal efficiency. However, its substantial latent heat of vaporization also poses cold-start challenges, such as misfire and fuel film deposition. This study aims to investigate methanol spray morphology and spray-wall interaction using the Spray M injector from the Engine Combustion Network within a constant-pressure flow vessel. A recently developed unified numerical framework capable of modeling both flash and non-flash boiling sprays is validated against experimental liquid volume fraction data acquired via 3-D computed tomography. Here, the results reveal that flash boiling significantly alters the spray morphology, leading to smaller droplets and spray collapse due to enhanced air-entrainment-induced turbulence. Quantitative agreement between experiments and simulations confirms this behavior. Coupled 0-D equilibrium and 3-D computational fluid dynamics analyses show that flash boiling accelerates evaporation and reduces fuel residence time, while non-flash conditions maintain a persistent liquid core more susceptible to wall wetting. Wall temperature diagnostics reveal that spray collapse alters heat transfer patterns by shifting cooling effects. Mixture fraction analysis indicates that evaporation is primarily governed by shear-layer turbulence, though deviations from adiabatic equilibrium mixing emerge under low-turbulence conditions. Finally, increasing fuel, ambient, and wall temperatures reduces wall wetting and film thickness, mitigating cold-start risks. These findings enhance the understanding of methanol sprays’ behavior and support its adoption as a viable, alternative fuel for ICEs.

Engine Combustion Network↗
DOE OSTI2025

Evaluating design safety margins in the American Society of Mechanical Engineers graphite core components design-by-analysis assessments

Graphite is an important material being used for core components in next-generation high-temperature gas-cooled nuclear reactors. The selection of graphite grade for a specific Designer is a complex task, dependent on reactor conditions, component functionality, and required reliability. The American Society of Mechanical Engineers (ASME) provides two semi-probabilistic design-by-analysis assessments to evaluate graphite core components against design reliability targets. The simplified assessment uses a 2-parameter Weibull distribution to describe the graphite grade’s tensile-strength distribution to establish component stress limits. The full assessment uses the 3-parameter Weibull distribution and a modified Weakest-Link Theory approach to calculate a component design probability of failure. The paper defines recommended assessment rules, which are the as-written simplified assessment and the full assessment with parameter lower bounds, the modulus update with threshold reduction, and the 2027 grouping rules. Code rules are applied to three grades: 2114, IG-110, and NBG-18. The baseline margin calculation is developed using the experimental tensile dogbone specimen. Percent margin is defined as the percent reduction in the median experimental load to obtain the allowable load per ASME assessments. Under the recommended rules, the SRC–1 margin in the simplified assessment ranged from 40.2 % to 52.7 % among the grades in this study and from 36.1 % to 49.8 % in the full assessment. The full assessment only decreases the margins by 2.5–4.5 % for the SRC-1 components and 0–1.5 % for the SRC-2 components for this baseline case. Margin is inversely related to material median strength (i.e., the strongest grade, 2114, has the lowest margin).

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Evaluation of Maximum Allowable Working Pressure and Svensson Burst Pressure Recommended in API 579-1 2021 Edition

Abstract API 579-1/ASME FFS-1 2021 Edition provides the minimum wall thickness, the maximum allowable working pressure (MAWP), and the membrane stress equations for thin and thick-walled cylindrical shells subject to internal pressure in Section 2C.3.3.1 of Appendix 2C – Thickness, MAWP, and Stress Equations for an FFS Assessment. The minimum wall thickness and MAWP are determined using the hoop stress and the Tresca yield criterion. Section 2C.7 – Estimation of Burst Pressure newly added the Svensson method for calculating burst pressure of cylindrical shells under internal pressure, where the plastic yielding is characterized by the von Mises yield criterion. For thin-walled cylinders, the von Mises flow solution of burst pressure in Equation (2C.179) was recommended. For thick-walled cylinders, an implicit burst pressure solution in an integral equation (2C.176) was recommended. But this integral equation is inconvenient to use in practice. It is well known that the classic plasticity theory includes the Tresca and von Mises yield criteria, with the Tresca criterion predicting a lower bound solution and the von Mises criteria predicting an upper bound solution. In addition, the present author developed an average shear stress yield criterion that can determine more accurate limit and burst pressures for thin and thick-walled cylinders. This work uses these three yield criteria to evaluate the minimum required wall thickness, MAWP and Svensson burst pressure recommended in the API 579 code.

burst pressure↗
DOE OSTI2025

ALARA Review for Venting of Flanged Tritium Waste Containers (FTWCs) at TA-54

This project will vent headspace hydrogen and oxygen from specialized high-pressure storage vessels called flanged tritium waste containers (FTWCs). There are four of these containers located in Los Alamos National Laboratory’s (LANL’s) Technical Area 54 (TA-54), Building 1028. This building is in the southwest corner of LANL’s Material Disposal Area G. The vented headspace gas is expected to contain tritium in the form of water vapor, elemental hydrogen or a combination of both. The venting operation is expected to take place in 2025. There will be a series of operational readiness reviews prior to venting activities commencing. The FTWCs at TA-54 contain tritium-contaminated metal parts and molecular sieve media, which is a pebble-like material used to absorb water vapor from the air. This molecular sieve media inside the FTWCs is contained in metal canisters, along with some loose media material in bags. Over time, tritiated water vapor that had been adsorbed onto the media can become liberated into the FTWC headspace gas. Radiolysis can cause separation of the water vapor into its hydrogen and oxygen components, resulting in the potentially hazardous gas mixture within the FTWC. LANL has determined that continued tritium storage in these containers can pose an unsafe condition due to possible hydrogen and oxygen gas buildup within the FTWCs with a potential for explosion if sparks are generated within the FTWCs. To mitigate this hazard, the FTWCs will be stabilized by venting them in-place to remove hazardous gases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI1991

Pressure Safety Training (Rev. 8)

This is the workbook for the Pressure Safety Training Course. It is intended as a reference manual and guide for all work with pressurized liquids or gases. This workbook contains basic references to make work with pressure safer. It is intended to supplement classroom instruction, rather than serve as a definitive text on pressure. Earlier versions of the manual were intended specifically for training at Lawrence Livermore National Laboratory. This revision is a generic version intended for training at all DOE facilities. The information in the Standards chapter is from the LLNL Health and Safety Manual. It is included here as a convenient reference and guide for developing similar standards at your own facility.

42 ENGINEERING↗
DOE OSTI2025

Evaluation of Maximum Allowable Working Pressure and Svensson Burst Pressure Recommended in API 579-1 2021 Edition

ABSTRACT API 579-1/ASME FFS-1 2021 Edition provides the minimum wall thickness, the maximum allowable working pressure (MAWP), and the membrane stress equations for thin and thick-walled cylindrical shells subject to internal pressure in Section 2C.3.3.1 of Appendix 2C – Thickness, MAWP, and Stress Equations for an FFS Assessment. The minimum wall thickness and MAWP are determined using the hoop stress and the Tresca yield criterion. Section 2C.7 – Estimation of Burst Pressure newly added the Svensson method for calculating burst pressure of cylindrical shells under internal pressure, where the plastic yielding is characterized by the von Mises yield criterion. For thin-walled cylinders, the von Mises flow solution of burst pressure in Equation (2C.179) was recommended. For thick-walled cylinders, an implicit burst pressure solution in an integral equation (2C.176) was recommended. But this integral equation is inconvenient to use in practice. It is well known that the classic plasticity theory includes the Tresca and von Mises yield criteria, with the Tresca criterion predicting a lower bound solution and the von Mises criteria predicting an upper bound solution. In addition, the present author developed an average shear stress yield criterion that can determine more accurate limit and burst pressures for thin and thick-walled cylinders. This work uses these three yield criteria to evaluate the minimum required wall thickness, MAWP and Svensson burst pressure recommended in the API 579 code.

burst pressure↗
DOE OSTI2026

Department of Transportation PHMSA Aerosol Spray Project: Phase-0

This report discusses the work conducted at Sandia National Laboratories during the preliminary phase (Phase-0) of the Department of Transportation (DOT) Pipeline and Hazardous Materials Safety Administration (PHMSA) project tasked to better understand what happens to a high-pressure liquid canister or vessel during a fire in which an accidental instantaneous release occurs. Phase 0 had two main objects: (1) to establish a methodology for the high temperature and pressure spray vessel release and (2) to characterize the spray droplet formation. For this test series, diagnostic equipment such as the Malvern Spraytec, high-speed photometric cameras, pencil gauges, and thermocouples were used. Additionally, the effect of surface tension on the particle size distribution was evaluated with 1-liter of distilled water and with the same including the addition of 0.5% soap/water mixture. Results from this effort indicated that the plume formed from the instantaneous release in all conditions primarily included two distinct particle size distributions including 217-312µm and 0.53µm on average. Soapy water formed a higher concentration of smaller mist (0.53µm) than distilled water, potentially due to decreased surface tension with the added surfactant. Though results showed good correlation to certain particle size distributions it is encouraged to conduct additional tests like this with a wider range of liquids with different properties, which could affect the overall particle size distribution when released.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Generalizing synthetic data-trained acoustic predictive models to real-world measurements

Acoustic Resonance Spectroscopy (ARS) is highly sensitive to structural properties such as material, geometry, and environmental conditions; as a consequence, it can noninvasively measure internal properties that are unobservable by most other methods. Because of its sensing capabilities and low implementation cost and complexity, ARS has potential as a paradigm shift in noninvasive sensing, characterization, and monitoring applications. However, extracting specific properties from ARS measurements, comprising the vibration spectrum of a test object, is challenging due to the sensitivity of the spectra to other structural changes not being measured, e.g. manufacturing tolerances, component coupling, environmental variation, etc. Neural Networks are promising tools for identifying trends in ARS measurements, but their training typically requires large datasets, which are often impractical to obtain for real-world systems. Synthetic data can be simulated efficiently, but discrepancies between synthetic and real-world data frequently lead to poor generalization when testing on the real-world data. We propose a novel ARS model training framework that enables networks trained exclusively on synthetic ARS data to generalize effectively to real-world measurements. Our approach leverages the Correlation Alignment (CORAL) technique to enforce the extraction of features common to both synthetic and real-world domains. As a case study, we demonstrate noninvasive ARS-based pressure measurements in sealed systems. Finite element method (FEM) simulations were used to generate synthetic training data across diverse vessel configurations and pressure conditions, and model performance was then tested on real-world measurements. We demonstrate that robust machine learning models for ARS can be developed without large real-world datasets, significantly broadening the applicability of ARS for noninvasive sensing. Moreover, the approach is extensible to other sensing modalities where synthetic data are abundant but real-world data are limited.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Integrated Simulation of Weld Residual Stress Evolution and Crack Propagation Using XFEM

Nuclear power plant components operate in environments that promote multiple degradation mecha- nisms, several of which involve crack initiation and growth. An ongoing effort in the U.S. Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is developing a general capability within the Multiphysics Object Oriented Simulation Environment (MOOSE) framework for simulating three-dimensional crack growth under a range of driving conditions, including fatigue, stress corrosion cracking (SCC), brittle fracture, and stress-relaxation cracking. This report demonstrates an end-to-end workflow that uses this capability to model weld-residual-stress-driven SCC in the J-groove weld of a pressurized-water reactor control rod drive mechanism penetration in the vessel head. The workflow consists of a thermomechanical welding simulation with temperature-dependent plasticity, followed by cooldown to ambient conditions, and a restart of the simulation using the MOOSE extended finite element method (XFEM) module to propagate a three-dimensional crack through the residual stress field. New welding capabilities were developed to properly initialize newly activated elements in the weld region, and robustness improvements were made to the mesh-based algorithm for defining cutting planes in the 3D XFEM algorithm, allowing it to handle complex crack fronts and stress fields. Together these advances allowed the simulated SCC crack to grow from an initial elliptical flaw in the weld, across the weld, through the tube wall, and almost to the triple point (where the weld, tube, and reactor pressure vessel head intersect) over roughly 36 years of simulated service. These results demonstrate a workflow that can be extended to fully three-dimensional welding simulations and more complex crack interaction problems.

42 - ENGINEERING↗
DOE OSTI2024

Application of a Comprehensive Lagrangian–Eulerian Spark-Ignition Model to Different Operating Conditions

Increasing engine efficiency is essential to reducing emissions, which is a priority for automakers. Unconventional modes such as boosted and highly dilute operation have the potential to increase engine efficiency but suffer from stability concerns and cyclic variability. To aid engineers in designing ignition systems that reduce cyclic variability in such engine operation modes, reliable and accurate spark-ignition models are necessary. Here, in this article, a Lagrangian–Eulerian spark-ignition (LESI) model is used to simulate electrical discharge, spark channel elongation, and ignition in inert or reacting crossflow within a combustion vessel, at different pressures, flow speeds, and dilution rates. First the model formulation is briefly revisited. Then, the experimental and simulations setups are presented. The results showcase the model’s ability to predict the secondary circuit voltage, current, and power signals, in addition to the spark channel elongation, for the inert cases, or flame front growth, for the reacting cases. The results also compare simulation spark channel and flame growth plots to experimental Schlieren images at different instants in time. This work serves to highlight LESI’s ability to predict the characteristics of discharge and ignition across a variety of operating conditions.

42 ENGINEERING↗
DOE OSTI1994

Nuclear Safety [Vol. 35, No. 2, July-December 1994]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 179 Consideration of Postaccident Consequences in the Determination of Safety Objectives for Future Nuclear Power Plants in France, D. Queniart, A. Sugier, and J. Lochard; ACCIDENT ANALYSIS: 187 Nuclear Safety Research: The Phebus FP Severe Accident Experimental Program, P. von der Hardt, A. V. Jones, C. Lecomte, and A. Tattegrain; 205 Containment Performance Analysis of the Advanced Neutron Source Reactor at the Oak Ridge National Laboratory, S. H. Kim, R. P. Taleyarkhan, and V. Georgevich; 213 Assessment of Fission Product Deposits in the Reactor Coolant System: The DEVAP Program, G. Le Marois and M. Megnin; 222 Erratum to “A Review of the Available Information on the Triggering Stage of a Steam Explosion," Vol. 35, No. 1, CONTROL AND INSTRUMENTATION: 223 Effects of Normal Aging on Calibration and Response Time of Nuclear Plant Resistance Temperature Detectors and Pressure Sensors, H. M. Hashemian; DESIGN FEATURES: 235 Defense in Depth Against the Hydrogen Risk—A European Research Program, F. Fineschi; ENVIRONMENTAL EFFECTS: 246 Technical Note: A Preliminary Analysis of the Risks to Hong Kong Resulting from Potential Accidents of Daya Bay Nuclear Power Plant, Z. Shi and X. Wei; OPERATING EXPERIENCES: 253 Reactor Shutdown Experience, Compiled by J. W. Cletcher; SPECIAL SECTION ON TMI-2 VESSEL INVESTIGATION PROJECT: 256 Three Mile Island—New Findings 15 Years After the Accident A. M. Rubin and E. Beckjord; 269 Relocation of Molten Material to the TMI-2 Lower Head, J. R. Wolf, D. W. Akers, and L. A. Neimark; 280 Insight Into the TMI-2 Core Material Relocation Through Examination of Instrument Tube Nozzles, L. A. Neimark; 288 Physical and Radiochemical Examinations of Debris from the TMI-2 Lower Head, D. W. Akers and B. K. Schuetz; 301 Results of Metallographic Examinations and Mechanical Tests of Pressure Vessel Samples from the TMI-2 Lower Head, D. R. Diercks and G. E. Korth; 313 Margin-to-Failure Calculations for the TMI-2 Vessel, J. Rempe, L. Stickler, S. Chavez, G. Thinnes, R. Witt, and M. Corradini; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 328 1993 Accident Sequence Precursor (ASP) Program Results, L. N. Vanden Heuvel, J. W. Cletcher, D. A. Copinger, J. W. Minarick, B. W. Dolan, and P. D. O’Reilley; RECENT DEVELOPMENTS: 339 Reports, Standards, and Safety Guides, D. S. Queener; 345 Proposed Rule Changes as of June 30, 1994; ANNOUNCEMENTS: 234 Thirty-First Annual Meeting of the National Council on Radiation Protection and Measurements; 356 1995 International Incineration Conference; 358 Fifth International Controls and Instrumentation Conference; 359 ANS International Topical Meeting on Safety of Operating Reactors; 359 Fifth International Conference on Nuclear Criticality Safety; 360 International Conference on Probabilistic Safety Assessment Methodology and Applications; 351 The Authors; 357 Reviewers of Nuclear Safety, Vol. 35.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Effect of Thermal Aging on Microstructure and Stress Corrosion Cracking Behavior of an Alloy 152 1st Layer Butter Weldment

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40- 80 years. Likewise, water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is critical for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for different durations up to 75,000h (equivalent to 60 years of reactor service). The microstructural characterization by means of synchrotron X-ray conducted in small, 0.2 mm - step line scans in the high-deformation regions of the weld root – covering areas spanning from the weld heat affected zone (HAZ) in Alloy 690 to the weld and weld butter on LAS - did not show evidence of LRO in any of the three Alloy 152 heats aged at 370°C and 450°C to an equivalent of 60 years of service. However, the first weld butter layer has high levels of deformation and is highly susceptible to SCC even in its non-aged condition. Nanohardness testing confirmed the extreme hardening with aging (ΔHV ≅ 100) at two locations within this weldment. In absence of LRO, hardening is suspected to be due to thermally-induced Cr carbide precipitation and coarsening. Testing in a primary water environment of the 1st layer of Alloy 152 weld butter aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloys. Similarly, the SCC CGR response of the aged weld butter does not appear to show a deterioration in performance, however, the difficult-to-test weldment geometry may affect the test results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

The Effect of Thermal Aging on the Performance of High-Cr Ni-based Alloys in Primary Water Environment

Nickel-based Alloy 690, and the associated weld Alloys 52 and 152, are used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels. They are chosen for their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate beyond their first or second license renewal (e.g., 40 to 60 years or beyond 60 years). Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear power plants. Moreover, Ni-Cr alloys are being considered for high-level radioactive waste disposal containers that will be required to contain the waste for at least 10,000 years.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Operation of helium sub-atmospheric multistage cryogenic centrifugal compressor trains: Part 1 – Steady state modeling and speed ratio selection

Helium cryogenic systems which can provide cooling below the normal boiling point of helium (approximately 4.2 K) are often required by superconducting radio-frequency niobium resonators utilized in modern high-energy particle accelerators. Achieving temperatures below 4.2 K generally involves operating a cryogenic vessel with liquid helium under sub-atmospheric conditions, thereby lowering the saturation pressure and corresponding saturation temperature. Over the last several decades, multi-stage cryogenic centrifugal compressor trains (CC’s) have been operated efficiently and reliably within large-scale cryogenic systems to continuously evacuate helium vapor generated by a device within the vessel, maintaining sub-atmospheric conditions in the vessel while pressurizing the return vapor to above atmospheric conditions. Traditionally, these CC systems have been operated using empirically derived control philosophies and insight gathered from previous operational experience. Recent efforts at the Facility for Rare Isotope Beams (FRIB) have been aimed at the development of a theoretical basis to characterize the operation of multi-stage cryogenic centrifugal compressor train and utilizing predictive model results to generate control parameters. The objective of this research was identifying operational points which adequately balance cryogenic system efficiency, stability, and overall ease of operation. Furthermore, this manuscript provides an overview of the predictive model development, characterization of the FRIB cryogenic centrifugal compressors and implementation of the predicted performance results during steady-state system operation.

Compressor train control↗
DOE OSTI2025

Design and Analysis of a Mutual Inductance Level Sensor for Liquid Metals

Here, this article describes the design and analysis of an electromagnetic level sensor for use in high-temperature liquid metal systems. The mutual inductance level sensor (MILS) described in this work was fabricated using two single-conductor mineral insulated cables wrapped in a bifilar fashion around a stainless steel tube core and was housed in an isolating thimble that preserved the pressure boundary of the test vessel. Two sensor variations were fabricated that differ only in active length, 1016 and 1778 mm. Experimental data were collected using the 1016-mm sensor (MILS-MKII-040) that demonstrated a sensitivity of 9.2 μ V/mm in a room temperature testing stand that used solid aluminum as a surrogate for liquid metal. Experimental data were collected using the 1778-mm sensor (MILS-MKII-070) that demonstrated a sensitivity of 6.9 μ V/mm in the high-temperature (300 ° C) liquid sodium environment at the mechanisms engineering test loop (METL) of Argonne National Laboratory. The sensor performance was found to be repeatable over the course of several months, with roughly ±1% deviation from nominal output. Finite element models were developed in COMSOL Multiphysics that fully describe each test setup, and the models were validated using experimental data. The validated COMSOL models were used to perform an array of analyses that examined the performance of the sensor in differing environments. Maximizing the coil diameter inside the isolating thimble was found to maximize the signal and sensitivity of the sensor. An optimal operating frequency was found near 1000 Hz using both experimental data and COMSOL. The influence of a metallic thimble surrounding the sensor and a metallic sensor core was quantified and found to be negligible at the optimal operating frequency. The sensitivity of the sensor was quantified when monitoring the level of additional liquid metals. These include lead, lead-bismuth eutectic (LBE), sodium-potassium alloy (NaK), and lithium (in addition to sodium). The sensitivities were quantified using liquid metal properties at 350 ° C and 650 ° C. The geometry of the test stand model, all material properties used in the model, and the results are presented in a manner that allows the reader can replicate the model and perform additional analyses.

COMSOL↗