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At least 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Direct Numerical Simulation of the Flow through a Randomly Packed Pebble Bed

The proposition for molten salt and high-temperature gas-cooled reactors has increased the focus on the dynamics and physics in randomly packed pebble beds. Research is being conducted on the validity of these designs as a possible contestant for the fourth-generation nuclear power systems. A detailed understanding of the coolant flow behavior is required in order to ensure proper cooling of the reactor core during normal and accident conditions. In order to increase the understanding of the flow through these complex geometries and enhance the accuracy of lower-fidelity modeling, high-fidelity approaches such as direct numerical simulation (DNS) can be utilized. Nek5000, a spectral-element computational fluid dynamics (CFD) code, was used to develop DNS fluid flow data. The flow domain consisted of 147 pebbles enclosed by a bounding wall. In the work presented, the Reynolds numbers ranged from 430 to 1050 based on the pebble diameter and inlet velocity. Characteristics of the flow domain such as volume averaged porosity, axial porosity, and radial porosity were studied and compared with correlations available in the literature. Friction factors from the DNS results for all Reynolds numbers were compared with correlations in the literature. The first- and second-order statistics show good agreement with the available experimental data. Turbulence length scales were analyzed in the flow. Reynolds stress anisotropy was characterized by utilizing invariant analysis. Overall, the results of the analysis in this study provide deeper understanding of the flow behavior and the effect of the wall in packed beds.

Yildiz, Mustafa Alper↗
DOE OSTI2026

A comparison of wrought and powder metallurgical FeCrAl claddings under simulated LWR accident transients

Iron-chromium-aluminum (FeCrAl) alloys are potential accident tolerant fuel (ATF) cladding candidates for light-water reactors but are difficult to fabricate as thin-walled tubes via conventional cast-and-wrought routes. Powder metallurgy (PM) offers a manufacturing alternative with improved compositional control, but its transient accident performance has not been directly benchmarked against wrought variants. This study evaluates the burst behavior of commercially developed PM-processed FeCrAl alloys, PM-C26M (Fe-12Cr-6Al-2Mo) and the high precipitate density FA-SMT (Fe-22Cr-5Al-3Mo), under simulated light-water reactor accident transient conditions. Burst testing was conducted using the Severe Accident Test Station with heating rates of 5 °C/s and 50 °C/s and internal pressures ranging from 25 MPa to 100 MPa. PM-C26M reproduced wrought C26M burst behavior within 7–37 °C across the stress range, indicating that PM processing does not compromise transient strength. FA-SMT exhibited markedly higher burst temperatures and reduced heating-rate sensitivity, consistent with its engineered precipitate strengthening. FA-SMT rupture exhibited axial "unzipping" rather than the lateral tearing characteristic of PM- and wrought C26M. Post-test EBSD and fractography indicate that this behavior is strongly correlated with strain-gated intergranular void nucleation associated with the dense precipitate architecture of FA-SMT, a response absent in the comparatively clean PM-C26M matrix and consistent with rupture morphologies reported for oxide-dispersion strengthened (ODS) FeCrAl of similar base-matrix chemistry to PM-C26M. These findings highlight the potential of powder metallurgy as a viable fabrication route for ATF claddings from an accident performance standpoint.

Bell, Sam [ORNL] (ORCID:0000000251905657)↗
DOE OSTI2017

Simultaneous Independent Control of Tool Axial Force and Temperature in Friction Stir Processing

Maintaining consistent tool depth relative to the part surface is a critical requirement for many Friction stir processing (FSP) applications. Force control is often used with the goal of obtaining a constant weld depth. When force control is used, if weld temperature decreases, flow stress increases and the tool is pushed up. If weld temperature increases, flow stress decreases and the tool dives. These variations in tool depth and weld temperature cause various types of weld defects. Robust temperature control for FSP maintains a commanded temperature through control of the spindle axis only. Robust temperature control and force control are completely decoupled in control logic and machine motion. This results in stable temperature, force and tool depth despite the presence of geometric and thermal disturbances. Performance of this control method is presented for various weld paths and alloy systems.

force control↗
DOE OSTI2023

Improved Compaction Experiments and Modeling of Waste Isolation Pilot Plant Standard, Non-degraded, Waste Containers

A credible simulation of disposal room porosity at the Waste Isolation Pilot Plant (WIPP) requires a tenable compaction model for the 55-gallon waste containers within the room. A review of the legacy waste material model, however, revealed several out-of-date and untested assumptions that could affect the model’s compaction behavior. For example, the legacy model predicted non-physical tensile out-of-plane stresses under plane strain compression. (Plane strain compression is similar to waste compaction in the middle of a long drift.) Consequently, a suite of new compaction experiments were performed on containers filled with surrogate, non-degraded, waste. The new experiments involved uniaxial, triaxial, and hydrostatic compaction tests on quarter-scale and full-scale containers. Special effort was made to measure the volume strain during uniaxial and triaxial tests, so that the lateral strain could be inferred from the axial and volume strain. These experimental measurements were then used to calibrate a pressure dependent, viscoplastic, constitutive model for the homogenized compaction behavior of the waste containers. This new waste material model’s predictions agreed far better with the experimental measurements than the legacy model’s predictions, especially under triaxial and hydrostatic conditions. Under plane strain compression, the new model predicted reasonable compressive out-of-plane stresses, instead of tensile stresses. Moreover, the new model’s plane strain behavior was substantially weaker for the same strain, yet substantially stronger for the same porosity, than the legacy model’s behavior. Although room for improvement exists, the new model appears ready for prudent engineering use.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Thermal shock resistance of lightweight cements developed for geothermal conditions

Cements are a critical component in well construction, as they act to prevent well fluid and gas escape, prevent corrosion of the casing, and strengthen the wellbore to prevent deformation. Under the high temperature/pressure conditions common in geothermal systems, the injection of cold water for energy production is expected to induce cyclic damage to the borehole cement through the rapid temperature fluctuations. These “thermal shocks” are expected to cause casing shrinkage, annulus formation, and cement tensile stresses. To understand the effect of cold water injection on the wellbore environment, a set of rock-cement-steel samples were created to simulate the structure of a geothermal well. Lightweight thermally-insulating cement blends were tested under thermal shock conditions in this study. In each test, the samples were pressurized to an effective pressure of ~3.5 MPa and placed at high temperatures. Thermal shocks were performed by injecting cold water (~10-15 °C) through the samples at a constant rate while keeping the samples at high temperatures until the sample temperature stopped decreasing and deformation ceased. Eight thermal shock tests were conducted with each sample – two at 100 °C and six at 200 °C. Post-tests analysis was then conducted by cutting open each sample to examine the damage in each component of the simulated wellbore. Experimental results suggest that all samples experienced similar degrees of axial and lateral contraction during cold water injection, but for the most part this contraction is recoverable when injection halts. Post-test analysis revealed that fly ash cenosphere pre-treatment had the best effect on improving thermal shock resistance in the cement blends. Thermomechanical modeling of likely stress paths experienced by the cements during heating/cooling cycles shows that elasto-plastic cement constitutive behavior results in most plastic strain occurring during the initial heating steps, with mostly elastic strain occurring during the thermal shock cycles. In conclusion, this agrees with experimental evidence, suggesting that cement damage from shocking occurs via other mechanisms such as chemical alteration, corrosion, and fatigue.

36 MATERIALS SCIENCE↗
DOE OSTI2017

BISON Fuel Performance Analysis of IFA-796 Rod 3 & 4 and Investigation of the Impact of Fuel Creep

In order to improve the accident tolerance of light water reactor (LWR) fuel, alternative cladding materials have been proposed to replace the currently used zirconium (Zr)-based alloys. Of these materials, there is a particular focus on iron-chromiumaluminum (FeCrAl) alloys because they exhibit slower oxidation kinetics in high-temperature steam than Zr-alloys. This should decrease the energy release due to oxidation and slow cladding consumption in the presence of high temperature steam. These alloys should also exhibit increased “coping time” in the event of an accident scenario by improving the mechanical performance at high temperatures, allowing greater flexibility to achieve core cooling. As a continuation of the development of these alloys, in-reactor irradiation testing of FeCrAl cladded fuel rods has started. In order to provide insight on the possible behavior of these fuel rods as they undergo irradiation in the Halden Boiling Water Reactor, engineering analysis has been performed using FeCrAl material models implemented into the BISON fuel performance code. This milestone report provides an update on the ongoing development of modeling capability to predict FeCrAl cladding fuel performance and to provide an early look at the possible behavior of planned in-reactor FeCrAl cladding experiments. In particular, this report consists of two separate analyses. The first analysis consists of fuel performance simulations of IFA-796 rod 4 and two segments of rod 3. These simulations utilize previously implemented material models for the C35M FeCrAl alloy and UO2 to provide a bounding behavior analysis corresponding to variation of the initial fuel cladding gap thickness within the fuel rod. The second analysis is an assessment of the fuel and cladding stress states after modification of the fuel creep model that is currently implemented in the BISON fuel performance code. Effects from modifying the fuel creep model were identified for the BISON simulations of the IFA-796 rod 4 experiment, but show that varying the creep model (within the range investigated here) only provide a minimal increase in the fuel radius and maximum cladding hoop stress. Continued investigation of fuel behavioral models will include benchmarking the modified fuel creep model against available experimental data, as well as an investigation of the role that fuel cracking will play in the compliance of the fuel. Correctly calculating stress evolution in the fuel is key to assessing fuel behavior up to gap closure and the subsequent deformation of the cladding due to PCMI. The inclusion of frictional contact should also be investigated to determine the axial elongation of the fuel rods for comparison with data from this experiment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Nodal root diameter and node number in maize ( Zea mays L.) interact to influence plant growth under nitrogen stress

Under nitrogen limitation, plants increase resource allocation to root growth relative to shoot growth. The utility of various root architectural and anatomical phenotypes for nitrogen acquisition are not well understood. Nodal root number and root cross-sectional area were evaluated in maize in field and greenhouse environments. Nodal root number and root cross-sectional area were inversely correlated under both high and low nitrogen conditions. Attenuated emergence of root nodes, as opposed to differences in the number of axial roots per node, was associated with substantially reduced root number. Greater root cross-sectional area was associated with a greater stele area and number of cortical cell files. Genotypes that produced few, thick nodal roots rather than many, thin nodal roots had deeper rooting and better shoot growth in low nitrogen environments. Fewer nodal roots offset the respiratory and nitrogen costs of thicker diameter roots, since total nodal root respiration and nitrogen content was similar for genotypes with many, thin and few, thick nodal roots. We propose that few, thick nodal roots may enable greater capture of deep soil nitrogen and improve plant performance under nitrogen stress. Synergistic interactions between an architectural and anatomical trait may be an important strategy for nitrogen acquisition. Understanding trait interactions among different root nodes has important implications in for improving crop nutrient uptake and stress tolerance.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Development of an Optimal Variable-Pitch Controller for Floating Axial-Flow Marine Hydrokinetic Turbines

This article discusses the development of an optimal variable-pitch controller for floating, axial-flow marine turbines. Recently, OpenFAST, an open-source wind turbine modeling tool, has been extended to model marine turbines. A controller is necessary to simulate marine turbines for different load cases using OpenFAST, which greatly impacts the performance of the energy system. Previous studies have designed controllers using a linearized model of the marine turbine, which can be time-consuming and require the expertise of a control engineer. In this study, we use an automated approach that uses generic models of the marine turbine to identify the controller gains, which can expedite the process of designing a controller. Using an optimizer to identify the control system parameters can additionally improve the controller's performance. The optimal controller tuned using such an approach results in a 20% reduction in the tower-base damage equivalent loading and better tracking of the rated generator speed and power.

axial flow↗
DOE OSTI2022

Relationships between fault characteristics and seismic responses in a large lab-scale tri-axial injection test conducted on a faulted Castlegate Sandstone

Here to investigate mechanisms causing microseismicity (M w < 2) at a CO 2 injection site, a large-scale triaxial block experiment was carried out on a faulted (saw-cut) cubic-meter of Castlegate Sandstone. The experiment consisted of injection tests at varying differential stresses, while monitoring and recording pore pressure and acoustic emissions (AEs). During the experiment, ~33,000 AEs and ~14 mm of horizontal displacement/slip, like a strike-slip fault movement, occurred. To understand the AE responses and ascertain fault characteristics near the located AEs, we modeled the topography of the fault surface, fault aperture, and fault-gouge thickness using pre- and post-experiment laser scans of the fault surface on each half of the block. Additionally, we characterized surface roughness parallel and perpendicular to slip. Models show crushing and flattening of the fault surfaces can be linked to the spatiotemporal distribution of AEs within 50 mm of the fault surface. Approximately 65% of AEs were in areas with small aperture (≤300 μm); thicker fault gouge was observed in adjacent areas with wider aperture and shows a two-fold reduction in grain size relative to unaltered Castlegate Sandstone. This work provides a conceptual understanding on fault surface evolution, which can be applied towards modeling of seismic slip.

58 GEOSCIENCES↗
DOE OSTI2020

Use of a Be-dome holder for texture and strain characterization of Li metal thin films via sin 2 (ψ) methodology

Residual strain in electrodeposited Li films may affect safety and performance in Li metal battery anodes, so it is important to understand how to detect residual strain in electrodeposited Li and the conditions under which it arises. To explore this Li films, electrodeposited onto Cu metal substrates, were prepared under an applied pressure of either 10 or 1000 kPa and subsequently tested for the presence or absence of residual strain via sin 2 (ψ) analysis. X-ray diffraction (XRD) analysis of Li films required preparation and examination within an inert environment; hence, a Be-dome sample holder was employed during XRD characterization. Results show that the Li film grown under 1000 kPa displayed a detectable presence of in-plane compressive strain (–0.066%), whereas the Li film grown under 10 kPa displayed no detectable in-plane strain. Here, the underlying Cu substrate revealed an in-plane residual strain near zero. Texture analysis via pole figure determination was also performed for both Li and Cu and revealed a mild fiber texture for Li metal and a strong bi-axial texture of the Cu substrate. Experimental details concerning sample preparation, alignment, and analysis of the particularly air-sensitive Li films have also been detailed. This work shows that Li metal exhibits residual strain when electrodeposited under compressive stress and that XRD can be used to quantify that strain.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Elastically-homogeneous lattice models of damage in geomaterials

This paper involves the development of the auxiliary stress approach for producing elastically-homogeneous lattice models of damage in geomaterials. The lattice models are based on random, three-dimensional assemblages of rigid-body-spring elements. Unlike conventional lattice or particle models, the elastic constants of a material (e.g., Young’s modulus and Poisson’s ratio) are represented properly in both global and local senses, without any need for calibration. The proposed approach is demonstrated and validated through analyses of homogeneous and heterogeneous systems under uni- and tri-axial loading conditions. Comparisons are made with analytical solutions and finite element results. Thereafter, the model is used to simulate a series of standard laboratory tests: (a) split-cylinder tests, and (b) uniaxial compressive tests of sedimentary rocks at the Horonobe Underground Research Laboratory in Hokkaido, Japan. Model inputs are based on physical quantities measured in the experiments. Finally, the simulation results agree well with the experimental results in terms of pre-peak stress-strain/displacement responses, strength measurements, and failure patterns.

3D irregular lattice↗
DOE OSTI2018

Engineering Prediction of Axial Wellbore Shear Failure Caused by Reservoir Uplift and Subsidence

Injection and production can cause significant regional uplift or settlement. We analytically evaluate the potential for cement-annulus failure in response to injection-induced deformation in a coupled casing/cement/rock poromechanical vertical-well system. Deformation is calculated with respect to the initial near-wellbore stress state, occurring immediately after cement curing. Tensile-failure and shear-failure lengths along this well are predicted using a stress-development-length method. The analytical model is verified by Abaqus modeling. Lastly, a sensitivity analysis identifies critical engineering-well-design parameters for ensuring wellbore-annulus integrity.

58 GEOSCIENCES↗
DOE OSTI2018

An optimization method for flexural bearing design for high-stroke high-frequency applications

A method for optimization of a high-stroke, high-frequency flexural bearing was completed. The main goal was to design a flexural bearing system as the energy restoration component of a one kW free piston linear engine alternator (LEA) operating at 90 Hz and maximum targeted displacement of 22 mm. Defined electricity output of 1 kW, with more than 30% efficiency, required engine operation under high speed and high stroke conditions. Under such challenging stroke and frequency requirements, a method of design was required to select between a wide range of parameters in flexural bearing design. A parametric CAD model was prepared and used in the optimization package of a finite element analysis (FEA) software. Four main parameters of flexural bearing geometry were identified and included the outer diameter, thickness, number of arms, and sweep angle of spiral cuts. Other design parameters including spiral gap width, shape factor and spiral start points angle were shown to be less important compared to these four main parameters in primary design and were examined separately. A neural network algorithm was used to investigate the interactions and effects of design parameters. The sensitivity of each parameter on output criteria such as maximum stress and natural frequency was examined and design charts developed. Methods for further modification of the spiral curve at end points were introduced to reduce the maximum stress level by up to 20%. Several steel alloys and a titanium-based alloy were identified as proper material candidates for high cycle applications and the final designed spring was manufactured and tested to validate the FEA results of axial stiffness and strain level throughout the flexure arms. The percent of the flexure’s moving mass was estimated to be 29% with FEA analysis and compared well with the experimental value of 31%. The stress/strain results of the FEA analysis matched with the experimental results – within ±5%.

42 ENGINEERING↗
DOE OSTI2020

Uniaxial compression of [001]-oriented CaFe 2 As 2 single crystals:the effects of microstructure and temperature on superelasticity Part I: Experimental observations

Micropillar compression experiments on [001]-oriented CaFe 2 As 2 single crystals have recently revealed the existence of superelasticity with a remarkably high elastic limit of over 10%. The collapsed tetragonal phase transition, which is a uni-axial contraction process in which As-As bonds are formed across an intervening Ca-plane, is the main mechanism of superelasticity. Usually, superelasticity and the related structural transitions are affected strongly by both the microstructure and the temperature. As such, in this study, we investigated how the microstructure and temperature affect the superelasticity of [001]-oriented CaFe 2 As 2 micropillars cut from solution-grown single crystals, by performing a combination of in-situ cryogenic micromechanical testing and transmission electron microscopy studies. Our results show that the microstructure of CaFe 2 As 2 is influenced strongly by the crystal growth conditions and by subsequent heat treatment. The presence of Ca and As vacancies and FeAs nanoprecipitates affect the mechanical behavior significantly. In addition, the onset stress for the collapsed tetragonal transition decreases gradually as the temperature decreases. These experimental results are discussed primarily in terms of the formation of As-As bonds, which is the essential feature of this mechanism for superelasticity. Our research outcomes provide a more fundamental understanding of the superelasticity exhibited by CaFe 2 As 2 under uni-axial compression.

36 MATERIALS SCIENCE↗
DOE OSTI2021

3D Mechanical Analysis of a Compact Nb 3 Sn IR Quadrupole for EIC

Abstract-The Electron Ion Collider (EIC) will require large aperture quadrupole magnets for the Hadron beam in the insertion region. Key requirements include high field, compact size, and tight control of the fringe fields. A 120 mm aperture, 308.4 mm outer diameter actively shielded Nb 3 Sn quadrupole model is under development to support these goals. This work is being carried out by a collaboration of BNL, JLAB and LBNL. A compact shell-based structure preloaded with a bladder and key system was developed for this project. In this paper, the effect of the compact structure on the mechanical behavior was investigated. In particular, the impact of the assembly tolerances and coil size variations on the actual coil stresses and bladder pressures was computed and compared with results from larger bladder and key structures developed for the LHC IR. The longitudinal preload is provided by stainless steel rods. Differently from other bladder and key magnets, the rods are first preloaded axially before coil axial load is applied. This new design aims to increase the overall stiffness of the system and reduce the longitudinal coil displacement during powering. Based on the results of a 3D mechanical analysis, the preliminary preload targets for the EIC quadrupole assembly will be reviewed and discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Status of Mock-up and Integration for Ultrasonic Deformation Sensor for TREAT Experiments

Fuel deformation (both axial and radial) information provides insights into fuel performance and failure limits. Traditionally, fuel deformation has been quantified using post-irradiation examinations due to the lack of an appropriate sensor for monitoring deformation in situ. Recent developments in sensor and instrumentation design have led to the use of linear variable differential transducers (LVDT) for monitoring axial strain in fuel during irradiation. Size and operational constraints limit the use of LVDT sensors for radial deformation monitoring, and alternatives are needed. One possible alternative to LVDT sensors is an ultrasonic sensor. Ultrasonic sensors monitor the interaction of high-frequency stress waves with the test object. The resulting response may be analyzed to determine the properties of the material, including stress, strain, microstructure, presence of defects, and the elastic constants. While ultrasonic measurements have been successfully applied for monitoring strain in a number of applications, their use for in-core measurements has been limited. Largely, the limitations are due to the challenges associated with designing sensors that can operate under typical in-core conditions. This report documents progress to date toward planning, construction, and testing of a mock-up test capsule/facility to be used for in-lab testing of ultrasonic displacement sensor designs and toward integration of the sensor into prototypic TREAT experiment designs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Integration Testing of Ultrasonic Deformation Sensor for TREAT Experiments

Fuel deformation (both axial and radial) information provides insights into fuel performance and failure limits. Traditionally, fuel deformation has been quantified using post-irradiation examinations due to the lack of an appropriate sensor for monitoring deformation in situ. Recent developments in sensor and instrumentation design have led to the use of linear variable differential transformers (LVDT) for monitoring axial strain in fuel during irradiation. Size and operational constraints limit the use of LVDT sensors for radial deformation monitoring, and alternatives are needed. One possible alternative to LVDT sensors is an ultrasonic sensor. Ultrasonic sensors monitor the interaction of high-frequency stress waves with the test object. The resulting response may be analyzed to determine the properties of the material, including stress, strain, microstructure, presence of defects, and the elastic constants. While ultrasonic measurements have been successfully applied for monitoring strain in a number of applications, their use for in-core measurements has been limited. Largely, the limitations are due to the challenges associated with designing sensors that can operate under typical in-core conditions. This report documents testing performed to confirm that the prototypic ultrasonic deformation sensor can be integrated into TREAT irradiation experiments using the SETH capsule.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2019

Second Annual Progress Report on Ultrasonic Sensors for TREAT Fuel Condition Measurement and Monitoring

Fuel deformation (both axial and radial) information provides insights into fuel performance and failure limits. Traditionally, fuel deformation has been quantified using post-irradiation examinations due to the lack of an appropriate sensor for monitoring deformation in situ. Recent developments in sensor and instrumentation design have led to the use of linear variable differential transformers (LVDT) for monitoring axial strain in fuel during irradiation. Size and operational constraints limit the use of LVDT sensors for radial deformation monitoring, and alternatives are needed. One possible alternative to LVDT sensors is an ultrasonic sensor. Ultrasonic sensors monitor the interaction of high-frequency stress waves with the test object. The resulting response may be analyzed to determine the properties of the material, including stress, strain, microstructure, presence of defects, and the elastic constants. While ultrasonic measurements have been successfully applied for monitoring strain in a number of applications, their use for in-core measurements has been limited. Largely, the limitations are due to the challenges associated with designing sensors that can operate under typical in-core conditions. The overall objective of this work is to design an ultrasonic sensor capable of rapid in-situ measurements of fuel rodlet dimensional changes during TREAT transient irradiation testing. This report summarizes the activities and research findings through the end of Year 2 of this three-year project.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗