Materials technology program for a compact fast reactor for space power
Production engineering and compatibility tests of Ta-8W-2Hf clad UN nuclear fuel element for use in lithium cooled space power unit reactors
Gluyas, R. E.↗
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A hydrogen energy carrier. Volume 2: Systems analysis
A systems analysis of hydrogen as an energy carrier in the United States indicated that it is feasible to use hydrogen in all energy use areas, except some types of transportation. These use areas are industrial, residential and commercial, and electric power generation. Saturation concept and conservation concept forecasts of future total energy demands were made. Projected costs of producing hydrogen from coal or from nuclear heat combined with thermochemical decomposition of water are in the range $1.00 to $1.50 per million Btu of hydrogen produced. Other methods are estimated to be more costly. The use of hydrogen as a fuel will require the development of large-scale transmission and storage systems. A pipeline system similar to the existing natural gas pipeline system appears practical, if design factors are included to avoid hydrogen environment embrittlement of pipeline metals. Conclusions from the examination of the safety, legal, environmental, economic, political and societal aspects of hydrogen fuel are that a hydrogen energy carrier system would be compatible with American values and the existing energy system.
Savage, R. L.↗
Materials technology for an advanced space power nuclear reactor concept: Program summary
The results of a materials technology program for a long-life (50,000 hr), high-temperature (950 C coolant outlet), lithium-cooled, nuclear space power reactor concept are reviewed and discussed. Fabrication methods and compatibility and property data were developed for candidate materials for fuel pins and, to a lesser extent, for potential control systems, reflectors, reactor vessel and piping, and other reactor structural materials. The effects of selected materials variables on fuel pin irradiation performance were determined. The most promising materials for fuel pins were found to be 85 percent dense uranium mononitride (UN) fuel clad with tungsten-lined T-111 (Ta-8W-2Hf).
Gluyas, R. E.↗
Thermal aging effects in refractory metal alloys
The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.
Stephens, J. R.↗
Thermal aging effects in refractory metal alloys
The alloys of niobium and tantalum are attractive from a strength and compatibility viewpoint for high operating temperatures required in materials for fuel cladding, liquid metal transfer, and heat pipe applications in space power systems that will supply from 100 kWe to multi-megawatts for advanced space systems. To meet the system requirements, operating temperatures ranging from 1100 to 1600 K have been proposed. Expected lives of these space power systems are from 7 to 10 yr. A program is conducted at NASA Lewis to determine the effects of long-term, high-temperature exposure on the microstructural stability of several commercial tantalum and niobium alloys. Variables studied in the investigation include alloy composition, pre-age annealing temperature, aging time, temperature, and environment (lithium or vacuum), welding, and hydrogen doping. Alloys are investigated by means of cryogenic bend tests and tensile tests. Results show that the combination of tungsten and hafnium or zirconium found in commercial alloys such as T-111 and Cb-752 can lead to aging embrittlement and increased susceptibility to hydrogen embrittlement of ternary and more complex alloys. Modification of alloy composition helps to eliminate the embrittlement problem.
Stephens, Joseph R.↗
Lessons Learned from Recent Testing in the Nuclear Thermal Rocket Element Environmental Simulator
The Nuclear Thermal Rocket Element Environmental Simulator (NTREES) facility is designed to perform realistic non-nuclear testing of nuclear thermal rocket (NTR) fuel elements and fuel materials. Although the NTREES facility cannot reproduce the neutron and gamma environment of an operating NTR, it can simulate the thermal hydraulic environment within an NTR fuel element to provide critical information on material performance and compatibility. The NTREES facility is currently being reconfigured with an all new suite of pyrometers, a new coil and feedthrough design along with a new gas sampling system for the mass spectrometer. Also new is the ability to perform chamber purges using argon. All of these modifications are the result of experiences gained through several years of testing various NTR components under a wide range of operating conditions. The testing details and the lessons learned from those tests are discussed in this presentation.
Emrich, William J., Jr.↗
Modeling Uncertainty in Time and Fuel Benefit Estimation for TASAR Operational Evaluation
The Traffic Aware Strategic Aircrew Requests concept aims to reduce weather-induced delays, improve route efficiency, and efficiently share route modification options by combining onboard avionics data, Automatic Dependent Surveillance-Broadcast data, and broadband internet data to generate optimal, traffic-compatible trajectory changes based on real-time traffic and weather data. Time and fuel benefits due to use of the Traffic Aware Planner (TAP) software can be estimated by taking the difference in predicted flight time and fuel usage before and after a TAP-inspired trajectory change is completed. Although TAP’s optimization algorithm predicts flight and fuel usage based on the current flight route and weather data, it does not account for possible air traffic controller-initiated trajectory changes, reroutes due to sudden weather changes, or other pilot/controller actions that may occur during flight. This paper introduces an approach for quantifying the uncertainty in estimated time and fuel benefits.
Burris, Joseph↗
Application of fuel/time minimization techniques to route planning and trajectory optimization
Rising fuel costs combined with other economic pressures have resulted in industry requirements for more efficient air traffic control and airborne operations. NASA has responded with an on-going research program to investigate the requirements and benefits of using new airborne guidance and pilot procedures that are compatible with advanced air traffic control systems and that will result in more fuel efficient flight. The results of flight testing an airborne computer algorithm designed to provide either open-loop or closed-loop guidance for fuel efficient descents while satisfying time constraints imposed by the air traffic control system is summarized. Some of the potential cost and fuel savings that are obtained with sophisticated vertical path optimization capabilities are described.
Knox, C. E.↗
Aluminum-Scandium Alloys: Material Characterization, Friction Stir Welding, and Compatibility With Hydrogen Peroxide (MSFC Center Director's Discretionary Fund Final Report, Proj. No. 04-14)
This Technical Memorandum describes the development of several high-strength aluminum (Al) alloys that are compatible with hydrogen peroxide (H2O2) propellant for NASA Hypersonic-X (Hyper-X) vehicles fuel tanks and structures. The yield strengths for some of these Al-magnesium-based alloys are more than 3 times stronger than the conventional 5254-H112 Al alloy, while maintaining excellent H2O2 compatibility similar to class 1 5254 alloy. The alloy development strategy is to add scandium, zirconium, and other transitional metals with unique electrochemical properties, which will not act as catalysts, to decompose the highly concentrated 90 percent H2O2. Test coupons are machined from sheet metals for H2O2 long-term exposure testing and mechanical properties testing. In addition, the ability to weld the new alloys using friction stir welding has also been explored. The new high-strength alloys could represent an enabling material technology for Hyper-X vehicles, where flight weight reduction is a critical requirement.
Lee, J. A.↗
Next Generation System Analysis Model Recently Added Features and Future Plans - Abstract
The Nuclear Waste Policy Act of 1982, as amended (NWPA 1982), established the federal government’s responsibility to accept spent nuclear fuel (SNF) and high-level radioactive waste (HLW) from waste owners and generators for ultimate disposition. SNF generated by the current fleet of commercial nuclear reactors is being stored at the reactor sites in spent fuel pools (SFPs) and in dry independent spent fuel storage installations (ISFSIs). The US Department of Energy Office of Nuclear Energy (DOE-NE) is developing an Integrated Waste Management Program (IWMP) comprising a suite of options and supporting analyses to enable future informed choices. The IWMP is applying integrated waste management system architecture analysis, system engineering, and decision analysis principles to inform potential future decisions regarding potential nuclear waste management system architectures. Architecture analyses of the IWM system are being conducted to support the future deployment of a comprehensive system for managing nuclear waste that considers all major aspects of the back end of the nuclear fuel cycle (i.e., transportation, storage, and disposal). The Next Generation System Analysis Model (NGSAM) is an agent-based simulation software tool designed for the express purpose of modeling the IWM system. NGSAM imports data from the Oak Ridge National Laboratory (ORNL) Unified Database (e.g., historic assembly information, thermal profiles for assembly heat, at-reactor dry storage loadings) to ensure that the simulation initializes with a realistic representation of the state of commercial SNF in the United States. Recent major enhancements that have been implemented into NGSAM since NGSAM was last presented at the WM2019 conference include: • Tracking of railroad escort and buffer car acquisition. • Addition of heavy haul and barge routes for some sites, as well as support for user-defined inter-modal routes. • Updates to the logic that checks the thermal maps prior to package transport. • Addition of an allocation method that predicts when reactor sites will pack assemblies from their pools for dry storage and allocates packages to those reactor sites in the preceding periods, favoring direct transport packages and reducing the number of packages that reactor sites pack for dry storage at their ISFSIs. • Addition of reactor site family operational limits, which are used to limit the number of loads from the pool and from dry storage at a given reactor site per year. • Support has been added for multiple canister loading maps and packages having multiple compatible transportation overpacks. • Updates in the handling of non-commercial fuel, including a new database containing data to support the updates. • Support for repackaging at reactor sites. • Implementing additional output reports or modifying existing reports. • User edits can now be created and edited via the NGSAM website. • Ability to load packages for dry storage at ISF pools. • Same-type package blending at DOE sites. • Support for multi-mode transloading at reactor sites. These new features have improved NGSAM capabilities and/or improve the user experience with the model and will be discussed in more detail. The initial NGSAM requirements for advanced reactor fuels, reprocessing, treatment, and conditioning are preliminary and are described at a high level in this paper: analysts will provide more specific requirements to the NGSAM team in the future. Additionally, there are many data needs associated with modeling advanced reactors in NGSAM, but many of the data or plans are still in progress and/or yet to be fully defined. However, this document describes an initial exploration of the data relevant to this program. Advanced reactor data will likely require revision as concepts evolve and new considerations are made. This is a technical paper that does not take into account contractual limitations or obligations under the Standard Contract for Disposal of Spent Nuclear Fuel and/or High-Level Radioactive Waste (Standard Contract) (10 CFR Part 961). For example, under the provisions of the Standard Contract, spent nuclear fuel in multi-assembly canisters is not an acceptable waste form, absent a mutually agreed to contract amendment. To the extent discussions or recommendations in this paper conflict with the provisions of the Standard Contract, the Standard Contract governs the obligations of the parties, and this paper in no manner supersedes, overrides, or amends the Standard Contract. This paper reflects technical work which could support future decision making by DOE. No inferences should be drawn from this paper regarding future actions by DOE, which are limited both by the terms of the Standard Contract and Congressional appropriations for the Department to fulfill its obligations under the Nuclear Waste Policy Act including licensing and construction of a spent nuclear fuel repository.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Subscale LOX/hydrogen testing with a modular chamber and a swirl coaxial injector
To support basic injector and chamber technology, the response of a modular calorimeter chamber to an injector with swirl coaxial elements was investigated. The tests supported both the Advanced Launch System (ALS) and the Space Shuttle Main Engine programs. Original test plans included chamber pressures up to 2250 psia, the current ALS engine criteria, but hardware limitations forced conditions to be reduced. With four different chamber configurations, a variety of data was obtained with chamber pressures ranging from 1483 psia to 1679 psia and mixture ratios from 5.24 to 6.90. The swirl coaxial injector showed good chamber wall compatibility, despite misaligned elements, and its high performance was independent of fuel. Heating rates and wall temperatures were acceptable and close to predict profiles, and after scaling to a chamber pressure of 2250 psia, heating rates remained acceptable. In addition, a chamber spool made with the vacuum plasma spray process survived hot-fire testing with no detrimental effects.
Elam, Sandra K.↗
Manufacturing and NDE of Large Composite Aerospace Structures at MSFC
NASA's vision for transportation to orbit calls for new vehicles built with new materials technology. The goals of this new launch system development are to improve safety, dramatically reduce cost to orbit, and improve vehicle turn around time. Planned Space Shuttle upgrades include new reusable liquid propellant boosters to replace the solid propellant boosters. These boosters are to have wings and return to the launch site for a horizontal landing on an airport runway. New single and two stages to orbit concepts are being investigated. To reduce weight and improve performance composite materials are proposed for fuel and oxidizer tanks, fuel feedlines, valve bodies, aerostructures, turbomachinery components. For large composite structures new methods of fabrication are being proposed and developed. Containment of cryogenic fuel or oxidizer requires emphases on composite material densification and chemical compatibility. Ceramic matrix and fiber composites for hot rotating turbomachinery have been developed with new fabrication processes. The new requirements on the materials for launcher components are requiring development of new manufacturing and inspection methods. This talk will examine new and proposed manufacturing methods to fabricate the revolutionary components. New NDE methods under consideration include alternative X-ray methods, X-ray laminagraphy, advanced CT, Thermography, new ultrasonic methods, and imbedded sensors. The sizes, complexity, use environment, and contamination restrictions will challenge the inspection process. In flight self-diagnosis and rapid depot inspection are also goals of the NDE development.
Whitaker, Ann↗
Porous matrix structures for alkaline electrolyte fuel cells
A number of advancements have been realized by a continuing research program to develop higher chemically stable porous matrix structures with high bubble pressure (crossover resistance) for use as separators in potassium hydroxide electrolyte fuel cells. More uniform, higher-bubble-pressure asbestos matrices were produced by reconstituting Johns-Manville asbestos paper; Fybex potassium titanate which was found compatible with 42% KOH at 250 F for up to 3000 hr; good agreement was found between bubble pressures predicted by an analytical study and those measured with filtered structures; Teflon-bonded Fybex matrices with bubble pressures greater than 30 psi were obtained by filtering a water slurry of the mixture directly onto fuel cell electrodes; and PBI fibers have satisfactory compatibility with 42% KOH at 250 F.
Vine, R. W.↗
High-resolution characterization of ceramic-metal interface of TiN coating on ferritic-steels for nuclear application
Advanced fuel cladding is critical for fast reactors, offering sufficient thermal conductivity, mechanical and dimensional stability and radiation tolerance of the cladding base material. Additionally, it must provide corrosion resistance and high temperature coolant compatibility on the cladding outer surface, as well as chemical stability on the cladding inner wall against fuel cladding chemical interaction (FCCI). TiN ceramic coating has been considered an effective diffusion barrier for inner and outer cladding-walls for enhanced performance. The TiN-metal interface microstructure and chemistry play a critical role in coating bond strength and integrity under harsh conditions. High-resolution transmission electron microscopy characterization of ceramic-metal interface at atomic resolution in unirradiated, irradiated and thermal cycled conditions were performed. The interface remained intact after irradiation up to 200 dpa or thermal cycling five times up to 550 °C. In conclusion, this work discusses the potential impact of these results on coating performance and design for advanced claddings.
36 - MATERIALS SCIENCE↗
APU diaphragm testing
The Auxiliary Power Unit (APU) fuel (hydrazine) tanks were removed from the Columbia Shuttle during major modification of the vehicle, because of long-term hydrazine compatibility concerns. The three tanks had been in service for 11 years. As part of an effort to determine whether the useful life of the fuel tanks can be extended, examination of the ethylene propylene rubber (EPR) diaphragm and the metal casing from one of the APU tanks was required. NASA Johnson Space Center Propulsion and Power Division requested the NASA Johnson Space Center White Sands Test Facility to examine the EPR diaphragm for signs of degradation that might limit the life of its function in the APU tank and to examine the metal casing for signs of surface corrosion. No appreciable degradation of the EPR diaphragm was noted. A decrease in the tensile properties was found, but tensile failure is considered unlikely because the metal casing constrains the diaphragm, preventing it from elongating more than a few percent. The titanium casing showed no evidence of surface corrosion.
Shelley, Richard↗
Fuel savings potential of the NASA Advanced Turboprop Program
The NASA Advanced Turboprop (ATP) Program is directed at developing new technology for highly loaded, multibladed propellers for use at Mach 0.65 to 0.85 and at altitudes compatible with the air transport system requirements. Advanced turboprop engines offer the potential of 15 to 30 percent savings in aircraft block fuel relative to advanced turbofan engines (50 to 60 percent savings over today's turbofan fleet). The concept, propulsive efficiency gains, block fuel savings and other benefits, and the program objectives through a systems approach are described. Current program status and major accomplishments in both single rotation and counter rotation propeller technology are addressed. The overall program from scale model wind tunnel tests to large scale flight tests on testbed aircraft is discussed.
Whitlow, J. B., Jr.↗
Toward a laminar-flow-control transport
Analyses were conducted to define a practical design for an advanced technology laminar flow control (LRC) transport for initial passenger operation in the early 1990's. Mission requirements, appropriate design criteria, and level of technology for the study aircraft were defined. The characteristics of the selected configuration were established, aircraft and LFC subsystems compatible with the mission requirements were defined, and the aircraft was evaluated in terms of fuel efficiency. A wing design integrating the LFC ducting and metering system into advanced composite wing structure was developed, manufacturing procedures for the surface panel design were established, and environmental and structural testing of surface panel components were conducted. Test results revealed a requirement for relatively minor changes in the manufacturing procedures employed, but have shown the general compatibility of both the selected design and the use of composite materials with the requirements of LFC wing surface panels.
Sturgeon, R. F.↗
Refractory oxide insulated thermocouple designed and analyzed for high temperature applications
Study establishes design criteria for constructing high temperature thermocouple to measure nuclear fuel pin temperature. The study included a literature search to determine the compatibility of material useful for thermocouples, a hot zone error analysis, and a prototype design for hot junction and connector pin connections.
Popper, G. F.↗