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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 OSTI2020

Effect of Air Plasma Sprayed Flash Bond Coatings on Furnace Cycle Lifetime of Disks and Rods

Air plasma sprayed (APS) flash coatings on high velocity oxygen fuel (HVOF) bond coatings are well known to extend the lifetime of thermal barrier coatings (TBCs). Recent work compared flash coatings of NiCoCrAlY and NiCoCrAlYHfSi applied to both rods and disk substrates of alloy 247. For rod specimens, 100 h cycles were used at 1100 °C in wet air. Both flash coatings significantly improved the lifetime compared to HVOF-only and vacuum plasma spray (VPS)-only MCrAlY bond coatings with no statistical difference between the two flash coatings. For disk specimens tested in 1 h cycles at 1100 °C in wet air, the NiCoCrAlY flash coating significantly outperformed an HVOF-only NiCoCrAlYHfSi bond coating and a NiCoCrAlYHfSi flash coating. The flash coatings formed a mixed oxide-metal zone that appeared to inhibit crack formation and therefore extend lifetime. In addition to the flash coating increasing the bond coating roughness, the underlying HVOF layer acted as a source of Al for this intermixed zone and prevented the oxide from penetrating deeper into the bond coating. Here, the lower Y+Hf content in the Y-only flash coating appeared to minimize oxidation in the flash layer, thereby increasing the benefit compared to a NiCoCrAlYHfSi flash coating.

42 ENGINEERING↗
DOE OSTI2025

Unsupervised Image-Based Classification of Corrosion Severity in Automobile Engine Connecting Rods

Corrosion in engine connecting rods is a critical issue in the automotive industry, potentially leading to catastrophic engine failure, monetary losses, and safety hazards. The labor shortage in the industry further emphasizes the need for fast, accurate, and automated corrosion detection methods to ensure appropriate surface treatments can be applied to restore component integrity. We present an unsupervised image-based framework for classifying corrosion severity in automobile engine connecting rods using short-wave infrared (SWIR) and telecentric grayscale imaging. We employ the structural similarity index measure (SSIM) as a dissimilarity metric and the k-medians clustering algorithm for classification. Our algorithm achieves an overall accuracy of 80.64% for SWIR images, with 100% accuracy in classifying highly corroded samples. For grayscale images, the method attains an overall accuracy of 77.42%, with 90.91% accuracy for highly corroded samples. The method’s ability to work with different imaging modalities and its high accuracy in identifying severe corrosion cases make it a promising tool for automated corrosion assessment in the automotive industry, potentially improving efficiency and safety in engine component maintenance.

42 ENGINEERING↗
DOE OSTI2022

Stability analysis of Monte Carlo burnup calculation based on PWR fuel rods

The existing Monte Carlo burnup algorithms may give some unstable results when using multiple burnable cells during burnup calculations. A very small time step is required to maintain the stability of the system, which pose some limits for the realistic applications. In this paper, we firstly repeat the instability issue by using a Monte Carlo code based on a typical PWR fuel rod model. Then, a theoretical stability analysis was carried out by using the perturbation theory in order to get a better understanding about the property of system stability. We determine a perturbation matrix which relates some main influence factors, such as the time step and the height of fuel rod, it can help people estimate the stability of burnup calculation system and the results are quantitatively consistent with the Monte Carlo code. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1951

Theory of thin-walled rods

Starting with the Love equations for bending of extensible shells, "principal stress states" are sought for a thin-walled rod of arbitrary but open cross section. Principal stress states exclude those local states arising from end conditions which damp out with distance from the ends. It is found that for rods of intermediate length, long enough to avoid local bending at a support, and short enough that elementary torsion and bending are not the most significant stress states, four principal states exist. Three of these states are associated with the planar distribution of axial stress and are equivalent to the engineering theory of extension and bending of solid sections. The fourth state resembles that which has been called in the literature "bending stress due to torsional", except that cross sections are permitted to bend and the shear along the center line of the cross section is permitted to differ from zero.

LOADS AND STRESSES, STRUCTURAL - TENSION↗
DOE OSTI2022

Design and Closed‐Loop Motion Planning of an Untethered Swimming Soft Robot Using 2D Discrete Elastic Rods Simulations

Despite tremendous progress in the development of untethered soft robots in recent years, existing systems lack the mobility, model‐based control, and motion planning capabilities of their piecewise rigid counterparts. As in conventional robotic systems, the development of versatile locomotion of soft robots is aided by the integration of hardware design and control with modeling tools that account for their unique mechanics and environmental interactions. Here, a framework for physics‐based modeling, motion planning, and control of a fully untethered swimming soft robot is introduced. This framework enables offline co‐design in the simulation of robot parameters and gaits to produce effective open‐loop behaviors and enables closed‐loop planning over motion primitives for feedback control of a frog‐inspired soft robot testbed. This pipeline uses a discrete elastic rods (DERs) physics engine that discretizes the soft robot as many stretchable and bendable rods. On hardware, an untethered aquatic soft robot that performs frog‐like rowing behaviors is engineered. Hardware validation verifies that the simulation has sufficient accuracy to find the best candidates for sets of parameters offline. The simulator is then used to generate a trajectory library of the robot's motion in simulation that is used in real‐time closed‐loop path following experiments on hardware.

Huang, Xiaonan↗
DOE OSTI2022

Triptycene-Based Molecular Rods for Langmuir-Blodgett Monolayers

In this report we introduce fully modular synthesis leading to three representative examples of rigid molecular rods that are intended to form sturdy monolayers on various surfaces. These molecules contain two triptycene units that are designed to interlock into a compact "double-decker" structure. Two of the three final products provided suitable crystals for X-ray diffraction (analyzed on synchrotron), allowing deeper insight into packing in the 3-D crystal lattice. The acidity of all three compounds were determined by capillary electrophoresis, and the pK a values ranged between 2.06-2.53. All three rigid rods easily formed Langmuir-Blodgett monolayers (LBMs) on the water-air interfaces, with the area per molecule equal to 55-59 Å 2 /molecule, suggesting tight intermolecular packing. The thickness of all three films reached ~19 Å after transfer to a gold (111) surface, meaning that individual molecules are tilted maximally 38° from the axis perpendicular to the surface. The structure of one of these films on a gold (111) surface was visualized by AFM. These geometrically unique molecules represent promising platforms with a wide scope of applicability in the supramolecular architecture.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Structural and functional analysis of the human cone‐rod homeobox transcription factor

Abstract The cone‐rod homeobox (CRX) protein is a critical K50 homeodomain transcription factor responsible for the differentiation and maintenance of photoreceptor neurons in the vertebrate retina. Mutant alleles in the human gene encoding CRX result in a variety of distinct blinding retinopathies, including retinitis pigmentosa, cone‐rod dystrophy, and Leber congenital amaurosis. Despite the success of using in vitro biochemistry, animal models, and genomics approaches to study this clinically relevant transcription factor over the past 25 years since its initial characterization, there are no high‐resolution structures in the published literature for the CRX protein. In this study, we use bioinformatic approaches and small‐angle X‐ray scattering (SAXS) structural analysis to further understand the biochemical complexity of the human CRX homeodomain (CRX‐HD). We find that the CRX‐HD is a compact, globular monomer in solution that can specifically bind functional cis‐regulatory elements encoded upstream of retina‐specific genes. This study presents the first structural analysis of CRX, paving the way for a new approach to studying the biochemistry of this protein and its disease‐causing mutant protein variants.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Bright NIR‐II Photoluminescence in Rod‐Shaped Icosahedral Gold Nanoclusters

Abstract Fluorophores with high quantum yields, extended maximum emission wavelengths, and long photoluminescence (PL) lifetimes are still lacking for sensing and imaging applications in the second near‐infrared window (NIR‐II). In this work, a series of rod‐shaped icosahedral nanoclusters with bright NIR‐II PL, quantum yields up to ≈ 8%, and a peak emission wavelength of 1520 nm are reported. It is found that the bright NIR‐II emission arises from a previously ignored state with near‐zero oscillator strength in the ground‐state geometry and the central Au atom in the nanoclusters suppresses the non‐radiative transitions and enhances the overall PL efficiency. In addition, a framework is developed to analyze and relate the underlying transitions for the absorptions and the NIR‐II emissions in the Au nanoclusters based on the experimentally defined absorption coefficient. Overall, this work not only shows good performance of the rod‐shaped icosahedral series of Au nanoclusters as NIR‐II fluorophores, but also unravels the fundamental electronic transitions and atomic‐level structure‐property relations for the enhancement of the NIR‐II PL in gold nanoclusters. The framework developed here also provides a simple method to analyze the underlying electronic transitions in metal nanoclusters.

Li, Qi↗
DOE OSTI2024

Sensitization and Mechanical Response of Cu‐Containing Steel Rods

The iron and steel manufacturing sector significantly adds to global greenhouse gas emissions, caused primarily by the carbothermic reduction of iron ore. Recycling scrap steel offers an effective decarbonization strategy but introduces impurities like copper (Cu) that can negatively impact mechanical properties. This study investigates the effects of Cu content and heat treatment on the mechanical performance and sensitization of steel wire rods for tire manufacturing. Steel rods with 0.04 and 0.21 wt% Cu are heated to 1050 or 1200 °C, then air quenched, or furnace cooled. Tensile testing coupled with microscopic analysis is used to evaluate mechanical properties and assess the sensitization effects. Higher Cu content leads to larger sensitized zones with increased Cu precipitation along grain boundaries. Ductility and toughness, crucial for wire drawability, are found to be reduced, despite higher ultimate strength. Slower furnace cooling is seen to result in smaller sensitized zones compared to air quenching, suggesting a pivotal role of cooling rate in sensitization control. The findings provide insights into optimize heat treatment parameters and Cu content limits, balancing mechanical performance and maintaining drawability for enhanced scrap steel recycling in tire production.

copper↗
DOE OSTI2023

A novel protocol to recycle zirconium from zirconium alloy cladding from used nuclear fuel rods

A potential new zirconium recycling protocol has been demonstrated using unirradiated Zircaloy-based claddings and depleted uranium oxide for the chemical removal of zirconium alloy cladding in used nuclear fuel (UNF) rods from light water reactors. This protocol is based on the application of three new scientific findings. First, a new lower temperature chlorination reaction of zirconium with sulfur monochloride is described. Second, the high solubility of zirconium chloride in thionyl chloride is used to separate it from uranium oxide fuel and fission and activation contaminants. Finally, in the third step, the zirconium chloride is purified by simple recrystallization from thionyl chloride. Utilizing sulfur chloride solvents for a lower temperature liquid-based chemical digestion and purification of zirconium alloy claddings reduces technical complications experienced by current high temperature gas phase chlorination strategies, such as contamination of product streams. This novel protocol has been demonstrated on a 3–50 g scale of unirradiated zirconium alloy, with no significant change in the time required for complete chlorination (3–4 h). This zirconium chlorination protocol has also been performed in the presence of depleted uranium oxide pellets. The depleted fuel pellets do not affect zirconium chlorination, and the chlorination protocol does not chemically or physically alter the fuel pellets. Finally, a preliminary description of an industrial protocol to recycle nuclear grade zirconium from UNF rods is presented.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Analysis of Small-Angle Neutron Scattering from Blends of Charged and Neutral Polymers Based on Rod–Coil Random Phase Approximation

Blends of charged and neutral polymers are of interest due to potential applications in rechargeable batteries. In this study, concentration fluctuations in blends of charged poly[lithium 3-(methacryloyloxy)propylsulfonyl-1-(trifluoromethanesulfonyl)imide] (PLiMTFSI) and neutral poly(ethylene oxide) (PEO) were investigated by small-angle neutron scattering (SANS). The scattering data were analyzed in the framework of the random phase approximation (RPA). Since ion dissociation can lead to stiffening, the charged polymers were approximated as rods, while the neutral polymers were assumed to be random coils. This approach works reasonably well at low weight fractions of charged polymers. For blends with higher weight fractions of the charged polymer, concentration fluctuations were highly suppressed, resulting in q-independent coherent structure factors that are inconsistent with the rod-coil RPA.

Lee, Jaeyong↗
DOE OSTI2023

Complex motion of steerable vesicular robots filled with active colloidal rods

Abstract While the collective motion of active particles has been studied extensively, effective strategies to navigate particle swarms without external guidance remain elusive. We introduce a method to control the trajectories of two-dimensional swarms of active rod-like particles by confining the particles to rigid bounding membranes (vesicles) with non-uniform curvature. We show that the propelling agents spontaneously form clusters at the membrane wall and collectively propel the vesicle, turning it into an active superstructure. To further guide the motion of the superstructure, we add discontinuous features to the rigid membrane boundary in the form of a kinked tip, which acts as a steering component to direct the motion of the vesicle. We report that the system’s geometrical and material properties, such as the aspect ratio and Péclet number of the active rods as well as the kink angle and flexibility of the membrane, determine the stacking of active particles close to the kinked confinement and induce a diverse set of dynamical behaviors of the superstructure, including linear and circular motion both in the direction of, and opposite to, the kink. From a systematic study of these various behaviors, we design vesicles with switchable and reversible locomotions by tuning the confinement parameters. The observed phenomena suggest a promising mechanism for particle transportation and could be used as a basic element to navigate active matter through complex and tortuous environments.

42 ENGINEERING↗
DOE OSTI2020

Experimental investigation of turbulent wake flows in a helically wrapped rod bundle in presence of localized blockages

In nuclear sodium fast reactors, bundles of rods are tightly packed into a triangular lattice, enclosed in a hexagonal duct, and each pin is spirally wrapped with a thin wire. Flow blockages can potentially impact the local flow characteristics and heat transfer mechanisms in the bundle due to its small subchannel size. The effects of the blockage on the flow structures and heat transfer mechanisms are important aspects that require an accurate investigation. In this study, the flow-field characteristics in the vicinity of a blockage located in the exterior subchannel of rod bundles with helically wrapped wires were experimentally investigated. The velocity fields in the exterior subchannel were acquired by applying matched-index-of-refraction and time-resolved particle image velocimetry (TR-PIV) techniques for Reynolds numbers of Re 1 = 4000 and Re 2 = 17 000, i.e., equivalent to Rew 1 = 19 600 and Rew 2 = 83 200, respectively, based on the blockage width. The results from the TR-PIV measurements revealed an arch-shaped vortex with a large flow recirculation and a pair of counter-rotating vortices in the wake region downstream of the blockage, which is commonly observed in the wake flow of bluff bodies. The relative lateral distance and angle between the two vortices decreased when the Reynolds numbers increased. Profiles of maximum turbulence intensity along the shear layers illustrated the transition process including the growth, peak, and decay along the flow direction. From the spectral analysis of the turbulent velocities extracted at points along the shear layer, the Strouhal numbers ( St ) representing the vortex shedding frequency were found to be St = 0.25 and St = 0.56 for the left and right shear layers, respectively. Characteristics of shear layers generated by the blockage in the exterior subchannel were investigated via the two-point cross correlation of fluctuating velocities. The patiotemporal cross correlations of turbulent velocities, computed at points in the region where the left shear layer exhibited rolling effects and vortex breakdowns, were considerably wider and longer. The convection velocity U c was estimated to be ~0.82 U m to 0.93 U m . Proper orthogonal decomposition (POD) analysis was applied to the instantaneous velocity fields to extract the statistically dominant flow structures. It was found that POD modes 2–3 and 4–5 formed the pair modes when the corresponding POD temporal coefficients depicted sinusoidal shapes and exhibited nearly circular orbits in the phase space. Spectral analysis of the POD temporal coefficients confirmed the vortex shedding frequencies detected in the analysis of turbulent velocities.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Turbulent flow characteristics in an 84-pin rod bundle for typical and damaged spacer grids

Hexagonal rod bundles arranged in a tightly packed triangular lattice are extensively used for heat transfer and energy generation applications. Staggered spacer grids are used to maintain the structural integrity of gas-cooled fast reactor (GFR) fuel assemblies, while inducing localized turbulence in flow. Damage to these spacer grids results in a disruption of flow fields within these hexagonal fuel bundles. Experimental flow visualizations are critical to identify the differences in local flow properties that the structural damage may cause. This experimental research investigates the flow-field characteristics at a near-wall and center plane in a prototypical 84-pin GFR fuel assembly. Newly installed typical spacers and spacers subject to naturally occurring damage due to material degradation over prolonged experimentation were investigated. Velocity fields were acquired by utilizing the matched-index-of-refraction method to obtain time-resolved particle image velocimetry measurements for a Reynolds number of 12 000. Reynolds decomposition statistical results divulged differences in the time-averaged velocity, velocity fluctuations, flow anisotropy, and Reynolds stress distributions. Galilean decomposition demarcated the influence of spacer grid damage on the velocity fields. To extract turbulent structures and elucidate mechanisms of flow instabilities, proper orthogonal decomposition analysis was employed. Reduced order flow reconstructions enabled the application of vortex identification algorithms to determine the spatial and statistical characteristics of vortices generated. This research work provides unique experimental data on the spacer grid condition-dependent flow. The results offer a deeper understanding of fluid dynamics behavior to support GFR rod bundle design efforts and computational fluid dynamics model validation.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Flash Heating of a Hollow Rod to Determine Thermal Properties

In a nuclear reactor, prolonged exposure to high neutron flux levels can change material properties of reactor components. Due to the danger posed to personnel by highly radioactive components such as spent fuel, noncontact methods must be used to determine these properties. The objective of the current research is to test the viability of using a flash-heating method to determine the thermal diffusivity of a silicon carbide (SiC) tube, which could be used as cladding for a nuclear fuel rod. The flash-heating experiment was conducted at Oak Ridge National Laboratory and temperature results were analyzed as a two-Dimensional cross section which assumed axial symmetry. The model was fitted iteratively to the temperature measurements using nonlinear regression which required values for thermal diffusivity, Biot number and a term to determine the magnitude of the heat absorbed by the flash. The method could be expanded in the future to estimate the thermal diffusivity of spent nuclear fuel rods in an effort to increase the certainty of new reactor designs using precise thermal properties throughout the core life. A statistical analysis of the results of this work is provided as part of the analysis.

McMasters, Robert L [Virginia Military Institute, ↗
DOE OSTI2020

Pitch Variation Experiments in Water-Moderated Square-Pitched U(6.9)O 2 Fuel Rod Lattices with Fuel to Water Volume Ratios Spanning 0.08 to 0.67

The US Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories. The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5% 235 U. The 7uPCX assembly is a water-moderated and -reflected array of aluminum-clad square-pitched U(6.90%)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMPTHERM- 096, LEU-COMP-THERM-097, and LEU-COMP-THERM-101. The twenty-seven critical experiments in this series were performed in 2020 in the SCX at the Sandia Pulsed Reactor Facility. The experiments are grouped by fuel rod pitch. Case 1 is a base case with a pitch of 0.8001 cm and no water holes in the array. Cases 2 through 6 have the same pitch as Case 1 but contain various configurations with water holes, providing slight variations in the fuel-to-water ratio. Similarly, Case 7 is a base case with a pitch of 0.854964 cm and no water holes in the array. Cases 8 through 11 have the same pitch as Case 7 but contain various configurations with water holes. Cases 12 through 15 have a pitch of 1.131512 cm and differ according to the number of water holes in the array, with Case 12 having no water holes. Cases 16 through 19 have a pitch of 1.209102 cm and differ according to number of water holes in the array, with Case 16 having no water holes. Cases 20 through 23 have a pitch of 1.6002 cm and differ according to number of water holes in the array, with Case 20 having no water holes. Cases 24 through 27 have a pitch of 1.709928 cm and differ according to number of water holes in the array, with Case 24 having no water holes. As the experiment case number increases, the fuel-to-water volume ratio decreases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Seven Percent Critical Experiment Core Analysis Approach on Fuel Rods – Core Configurations T155-NoMo, and T155-397Mo.

A series of experiments will be performed to test the integral effects of molybdenum on the reactivity of a critical system. These experiments will use the 7uPCX assembly with the 1.55 cm triangular pitch grid plates. Molybdenum sleeves, consisting of 19.6 inch long 0.5-inch nominal outside diameter molybdenum tubes with 0.031-inch nominal wall thickness and centering hardware, will be placed on some of the fuel rods in the array. The purpose of this analysis is to examine two configurations of the 7uPCX using the 1.55 cm triangular pitch grid plates in fully-reflected approach-to-critical experiments with the number of fuel rods in the array as the approach parameter. This document presents the results of the analysis that was done to allow completion of the 7uPCX Configuration Checklist from Appendix A of SPRF-AP-005 [SNL 2020] for the cores noted above. The checklists for these cores are shown in Appendix A.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Tritium Producing Burnable Absorber Rod (TPBAR) Cutterhead Test Report

The Tritium Extraction Facility (TEF) Target Rod Preparation (TRP) Tritium Producing Burnable Absorber Rod (TPBAR) Cutterhead is a specialized remote tubing cutter used to breach TPBARs (approximately 0.381 inch outside diameter x 0.336 inch inside diameter 316 stainless steel tubing). The cutterhead was originally designed by an external engineering firm - RTS Wright Industries. The bearing housing and drive plate, the main drive components, are designed to be fabricated from Nitronic 60, an anti-galling stainless steel, and coated with Dicronite® (Tungsten Disulfide) lubricating coating. These parts have galled after a limited number of cycles, damaging the fine 3.25-32 UN threads which drive the system. In some cases, destructive sectioning is required to remove the failed parts from the cutterhead. Cutterheads have been fabricated by multiple machine shops, with some cutterheads failing very quickly and some lasting more than 1,000 cuts. In 2019, Emery Corporation, now Toner Machining Technologies (TMT) was contracted to fabricate four (4) new complete sets of cutterheads. The newly fabricated cutterheads have not been able to pass the required acceptance test without the bearing housing and drive plate threads galling. TMT has tried multiple sets of Nitronic 60 bearing housing and drive plates; all have galled after less than 10 cuts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗