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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 199 records · Page 11

Understanding Flow Characteristics in Metal Additive Manufacturing

In fluid flow, the frictional effects from interior surfaces of flow components create pressure loss across the surface. Understanding this inherent pressure loss due to friction and other phenomena is important when designing a flow system. For conventional manufacturing, friction loss has been empirically studied and is well known in the engineering community. However, newer manufacturing techniques, such as laser powder bed fusion (LPBF), an additive manufacturing technique, need to be understood. The inherent flow conditions resulting from the additive processes were studied. Test samples were printed with the flow path oriented in the vertical direction with different channel diameters to characterize the inherent fundamental flow properties of the process. Moody diagrams were replicated for a greater understanding of possibilities and shortfalls when implementing LPBF into design applications. Experimental flow testing revealed that greater effective sand grain roughness resulted from this process when compared to conventional machining methods. This roughness did not correlate well to the average roughness measured with a laser scanning microscope but was consistent with the average particle size of the powder metal feedstock.

42 ENGINEERING↗

Digital data provenance for the power grid based on a Keyless Infrastructure Security Solution

In this work a data provenance system for grid-oriented applications is presented. The proposed Keyless Infrastructure Security Solution (KISS) provides mechanisms to store and maintain digital data fingerprints that can later be used to validate and assert data provenance using a time-based, hash tree mechanism. The developed solution has been designed to satisfy the stringent requirements of the modern power grid including execution time and storage necessities. Its applicability has been tested using a lab-scale, proof-of-concept deployment that secures an energy management system against the attack sequence observed on the 2016 Ukrainian power grid cyberattack. The results demonstrate a strong potential for enabling data provenance in a wide array of applications, including speed-sensitive applications such as those found in control room environments.

Sebastian Cardenas, David J.↗

Heat Pipe Enhanced Thermal Management System for GaN Switches in an Integrated Modular Motor Drive for Aircraft Propulsion

This paper presents the process of sizing a heat pipe enhanced thermal management system (TMS) for GaN switches in an integrated modular motor drive (IMMD) powering a 250 kW aircraft propulsion electric motor. A test setup mimicking the TMS and GaN switches assembly is constructed. The condenser chamber of the TMS is modeled in ANSYS Fluent while the GaN switches assembly is modeled in ANSYS Thermal allowing us to verify heat spreader temperature under test conditions and estimate GaN temperatures under test and actual application operating conditions.

DIRECT ENERGY CONVERSION↗

Status Update for the Bearing Test Article Design Development – FY2025

Argonne National Laboratory’s (ANL) Mechanism Engineering Test Loop (METL) team has completed the design of a new Bearing Test Article (BTA) to test mechanical bearings for sodium fast reactor (SFR) mechanism applications. Recognition of the need for further bearing testing arose due to failure of rolling element bearings during testing of components for in-vessel fuel handling machines (FHMs) conducted at ANL in the METL facility. While the initial concept of the BTA arose from a need for bearing testing for FHM applications, the BTA design is configurable to test bearings of various sizes, types, and materials submerged in liquid sodium. Requirements for loading, shaft speed, temperature, and bearing size range were chosen based on requirements for SFR fuel handling. Modular components in the test bearing housings and shaft sleeves allow the design to accommodate a wide range of bearing sizes without modification to the larger assembly. Loading will be applied with screw jacks on the air side of the test article that will be adjusted to apply radial, thrust, or combined loading conditions. Applied force will be measured by load cells in-line with the loading mechanisms. In FY25 we have completed the design of the test article that will be fabricated and undergo testing at the METL facility. Drawing packages for the fabrication of the test article have been drafted and are being reviewed to add part tolerances and we have started ordering off-the-shelf components. The report will summarize the development of the Bearing Test Article design starting with an overview of the entire test article, then a more detailed examination of the bearing test section, loading mechanisms, test article ports and seals, and support structures, including analysis that went into significant design choices.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Online PMU Missing Value Replacement Via Event-Participation Decomposition

We introduce a new method for online Phasor Measurement Unit (PMU) missing value replacement. Our approach allows us to decompose PMU event responses into a non-dynamic component (denoted the participation factor) that can be inferred directly from the past and a dynamic component that can be inferred directly from all other PMUs (denoted the event strength). When missing values occur, we can use these two components, which do not rely on the missing index, to estimate the correct value. The method is extremely fast and can easily be used for online applications. Furthermore, extensive testing on real power system event data reveals that our approach achieves state-of-the-art performance in terms of Mean Absolute Percent Errors (MAPEs) for PMU data dropped during event periods. Here, the method also yields an interpretable and simplified view of events for further analysis and applications. The method relies only on PMU data and does not take outside information such as network topology.

24 POWER TRANSMISSION AND DISTRIBUTION↗

COR-0011 Rev 6 MARVEL Project Code of Record

This Code of Record identifies the codes, standards, and procedures necessary to design, develop, construct, and startup the Microreactor Applications Research Validation and Evaluation (MARVEL) Project at the Materials and Fuel Complex (MFC) Transient Reactor Test (TREAT) Facility and the Idaho National Laboratory (INL). The MARVEL Project is an INL test microreactor funded by the United States Department of Energy (DOE) via the Microreactor Program (MRP). The goal of the project is to establish an operational nuclear applications test bed that can generate combined heat and power to enable integration and R&D with end-user technologies, as well as allow microreactor technologists to test next-generation control systems. The microreactor is a thermal reactor utilizing Uranium Zirconium Hydride (UZrH) fuel with review and authorization by the Department of Energy Idaho Operations Office (DOE-ID) for National Environmental Policy Act (NEPA) compliance, safety review, and supplemental readiness assessments for startup and operation. To enable rapid deployment, the MARVEL reactor will reside in the Transient Reactor Test (TREAT) Facility and utilize the existing operating Category B reactor facility, approved facility safety basis, operating crews, and recent re-start experience.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗

Angular scattering of protons through ultrathin graphene foils: Application for time-of-flight instrumentation

Space plasma instruments often rely on ultrathin carbon foils for incident ion detection, time-of-flight (TOF) mass spectrometry, and ionization of energetic neutral atoms. Angular scattering and energy loss of ions or neutral atoms in the foil can degrade instrument performance, including sensitivity and mass resolution; thus, there is an ongoing effort to manufacture thinner foils. Using new 3-layer graphene foils manufactured at the Los Alamos National Laboratory, we demonstrate that these are the thinnest foils reported to date and discuss future testing required for application in space instrumentation. We characterize the angular scattering distribution for 3–30 keV protons through the foils, which is used as a proxy for the foil thickness. We show that these foils are ~2.5–4.5 times thinner than the state-of-the-art carbon foils and ~1.6 times thinner than other graphene foils described in the literature. We find that the inverse relationship between angular scattering and energy no longer holds, reaffirming that this may indicate a new domain of beam–foil interactions for ultrathin (few-layer) graphene foils.

47 OTHER INSTRUMENTATION↗

Ku-band electron linac for battery-powered hand-portable 2-MeV X-ray generator

X-ray generators, producing radiation in MeV range, are a critical tool for radiography, non-destructive testing and security applications. Field operation of such source requires them to be hand-portable, autonomous and allow parameter adjustability. RF linear accelerators can serve as a flexible, reliable, and robust radiation generator alternative to dangerous radioisotopes and bulky betatrons that are currently used for field radiography if their size, weight, cost, and imaging performance are matched to these sources. Here, in this paper, we present the design and test results of a 2 MeV Ku-band electron linac for a hand-portable X-ray generator system for field radiography being developed by RadiaBeam. The dramatic scale of miniaturization and cost-reduction is achieved thanks to the implementation of innovative technologies such as air-cooled Ku-band air-traffic control magnetrons, a split accelerating structure fabrication technique, and solid-state Marx modulators. This paper presents the design of the first prototype of the accelerator, its operation from Li-Ion batteries, as well as high-power and beam measurements.

43 PARTICLE ACCELERATORS↗

Thermal Evaluation of the SAVY-4000 1 Quart Container at High Heat Loads

The SAVY-4000 Safety Analysis Report (SAR) was published in 2013 which established the design life of the container series through physical testing that meets applicable requirements from DOE M 441.1-1, Nuclear Material Packaging Manual. One critical requirement in DOE M 441.1-1 is to set a maximum heat load for the entire series to ensure that throughout the lifetime of the container, each of the components still performs within manufacture specifications. The original maximum decay heat limit has been defined within the SAVY-4000 SAR, which was accomplished by completing a series of tests that heat loaded the SAVY-4000 series and measured the steady state temperature and graded it against manufacture specifications. The container series is comprised of a corrosion resistant 316L stainless steel containment boundary, ceramic composite filter for the prevention of radiological particulate release and a chemically stable O-ring made of Viton ® . Currently, the SAVY 4000 maximum decay heat load is set at 25 Watts and the heat load expected during normal handling and storage is considered sufficient that the SAVY 4000 container requirements will not be the limiting factor for storage of most common material in use at TA-55, e.g. weapons grade oxide, americium, Pu-238 oxide and encapsulated heat sources. The SAVY 4000 lifetime was originally set as 5 years within the SAVY-4000 SAR, but in July 2019 the lifetime was extended to 15 years through a technical basis justification approved by the Department of Energy (DOE) Los Alamos Field Office. The 25 Watt limit applies to all SAVY 4000 container sizes; 1-quart, 2-quart, 3-quart, 5-quart, 8-quart, 12-quart, 5-gallon, and 10-gallon.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Directly Probing the Fracture Behavior of Ultrathin Polymeric Films

Understanding fracture mechanics of ultrathin polymeric films is crucial for modern technologies, including semiconductor and coating industries. However, up to now, the fracture behavior of sub-100 nm polymeric thin films is rarely explored due to challenges in handling samples and limited testing methods available. In this work, we report a new testing methodology that can not only visualize the evolution of the local stress distribution through wrinkling patterns and crack propagation during the deformation of ultrathin films but also directly measure their fracture energies. Using ultrathin polystyrene films as a model system, we both experimentally and computationally investigate the effect of the film thickness and molecular weight on their fracture behavior, both of which show a ductile-to-brittle transition. Furthermore, we demonstrate the broad applicability of this testing method in semicrystalline semiconducting polymers. We anticipate our methodology described here could provide new ways of studying the fracture behavior of ultrathin films under confinement.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DEVELOPMENT AND DEMONSTRATION TESTBED FOR THE REMOTE OPERATIONS AND MONITORING OF MICROREACTORS

The nuclear industry is rapidly developing many advanced-reactor concepts for near-term deployment in both traditional and non-traditional nuclear-powered applications. One such category of advanced reactor is the microreactor, a class of reactor with less than 20MWth power output, intended for applications where the economics or logistics of traditional power sources are difficult. This includes applications such as remote communities, mining sites, defense installations, or humanitarian and disaster-relief missions. One key enabling feature for the successful deployment of microreactors is a remote operations capability. Remote operations provide monitoring and control capabilities which can significantly reduce staffing costs by eliminating the need for licensed operators at each reactor facility and improve the economic viability for microreactor deployment. A remote concept of operations is not currently an established capability in the nuclear industry. In addition, no demonstration microreactor is expected to complete construction or go critical until at least 2026. This leaves two major capability gaps: the successful demonstration of a remote concept of operations for microreactors and a test bed suitable for said demonstration. Both gaps must be addressed in order to advance the remote concepts of nuclear operation and, more broadly, microreactors themselves from paper to reality. This paper aims to fill these gaps and describes a test bed that would support development and deployment of a remote concept of nuclear operations, initial experimental results from that test bed, and the application of the test bed and experimental results for a digital-twin-based remote concept of operations underdevelopment at Idaho National Laboratory (INL). The platform chosen as a remote concept of nuclear operations test bed is the Single Primary Heat Extraction and Removal Emulator, known as SPHERE, located at INL. SPHERE is a small-scale non-nuclear test bed that emulates thermal behavior of a microreactor. The small-scale and non-nuclear nature of SHPERE limit safety concerns associated with remote operations while still providing the physical response representative of a microreactor. A network connection was added to SPHERE that enables remote-monitoring capability. This allows for real-time data streaming to networked workstations, data historians, and human-machine interfaces (HMIs). These are all critical components in a remote concept of operations, thus providing a robust development and demonstration platform. An initial experiment was performed using the SPHERE remote operations testbed. This included running a comprehensively instrumented SPHERE through a series of steady-state and transient operating scenarios in both normal and abnormal operating conditions, all while streaming live test data to a remote HMI and data warehouse. This initial experiment served three purposes: (1) characterizing the response of SPHERE, (2) demonstrating the remote connection to SPHERE, and (3) providing a baseline data set for development of a digital-twin-based remote concept of operations that is under development at INL.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DEVELOPMENT AND DEMONSTRATION TESTBED FOR THE REMOTE OPERATIONS AND MONITORING OF MICROREACTORS

The nuclear industry is rapidly developing many advanced-reactor concepts for near-term deployment in both traditional and non-traditional nuclear-powered applications. One such category of advanced reactor is the microreactor, a class of reactor with less than 20MWth power output, intended for applications where the economics or logistics of traditional power sources are difficult. This includes applications such as remote communities, mining sites, defense installations, or humanitarian and disaster-relief missions. One key enabling feature for the successful deployment of microreactors is a remote operations capability. Remote operations provide monitoring and control capabilities which can significantly reduce staffing costs by eliminating the need for licensed operators at each reactor facility and improve the economic viability for microreactor deployment. A remote concept of operations is not currently an established capability in the nuclear industry. In addition, no demonstration microreactor is expected to complete construction or go critical until at least 2026. This leaves two major capability gaps: the successful demonstration of a remote concept of operations for microreactors and a test bed suitable for said demonstration. Both gaps must be addressed in order to advance the remote concepts of nuclear operation and, more broadly, microreactors themselves from paper to reality. This paper aims to fill these gaps and describes a test bed that would support development and deployment of a remote concept of nuclear operations, initial experimental results from that test bed, and the application of the test bed and experimental results for a digital-twin-based remote concept of operations underdevelopment at Idaho National Laboratory (INL). The platform chosen as a remote concept of nuclear operations test bed is the Single Primary Heat Extraction and Removal Emulator, known as SPHERE, located at INL. SPHERE is a small-scale non-nuclear test bed that emulates thermal behavior of a microreactor. The small-scale and non-nuclear nature of SHPERE limit safety concerns associated with remote operations while still providing the physical response representative of a microreactor. A network connection was added to SPHERE that enables remote-monitoring capability. This allows for real-time data streaming to networked workstations, data historians, and human-machine interfaces (HMIs). These are all critical components in a remote concept of operations, thus providing a robust development and demonstration platform. An initial experiment was performed using the SPHERE remote operations testbed. This included running a comprehensively instrumented SPHERE through a series of steady-state and transient operating scenarios in both normal and abnormal operating conditions, all while streaming live test data to a remote HMI and data warehouse. This initial experiment served three purposes: (1) characterizing the response of SPHERE, (2) demonstrating the remote connection to SPHERE, and (3) providing a baseline data set for development of a digital-twin-based remote concept of operations that is under development at INL.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Impurity gas monitoring using ultrasonic sensing and neural networks: forward and inverse problems

Ultrasonic sensing is a non-invasive technique for monitoring impurity gas composition in various industrial applications where safety and regulatory compliance are crucial. In this study, ultrasonic sensing and neural networks were used to analyze impurity gases (i.e., air and argon) in helium. An experimental platform was established to acquire ultrasonic data. In the forward problem, an artificial neural network (ANN) model was used to forecast the response and time-of-flight (TOF) based on the excitation, and argon and air concentrations. The inverse problem was solved using a convolutional neural network (CNN) to predict the argon and air concentrations given the ultrasonic response and excitation. The results showed that the ANN accurately predicted the ultrasonic response and the change in TOF with concentration. As the air concentration was increased from 0 to 9.8%, the TOF sensitivity to detect argon decreased by 39.8% and 16.1% from ANN and sound speed theory, respectively. The CNN demonstrated high accuracy in predicting concentrations for inputs in the testing dataset. The application of the trained CNN indicated that it over-predicts air concentration while under-predicting the argon concentration. To improve accuracy, the predicted air and argon concentrations should be corrected by -0.992% and 1.027% bias, respectively.

47 OTHER INSTRUMENTATION↗

Environmental Durability Assessment and Development of Subcomponent Test Methods for Advanced Materials in Marine Energy Applications

Marine energy developers are beginning to rely more heavily on advanced composite materials for their load-bearing structures. Understanding how these materials respond and degrade in harsh marine environments is a complex problem. Much research has been performed at smaller laboratory scales to understand the fundamental physical and chemical degradation mechanisms, but little structural testing research has been performed at larger scales to understand how these physical and chemical interactions scale and how they should be accounted for in the design process. The Advanced Materials project is a multilaboratory research collaboration that addresses these issues with the intention of reducing risks and barriers to marine energy developers wanting to adopt advanced composite materials. The National Laboratory of the Rockies has been playing a leading role in developing larger-scale testing infrastructure and test methods to validate complex numerical degradation models and standardize testing procedures to do so. This paper reviews past structural testing activities, how they have grown into current research activities, and how they will continue to evolve to directly address industry needs. This paper covers key research areas - large-scale water absorption and subsequent structural validation testing, qualification of bolted and adhesive connections, and combined submerged fatigue testing at increasing scales. It provides insights into the complex requirements for testing infrastructure and test method development to effectively qualify materials and certify marine energy structures for harsh marine environments. This research program paves the way for better guidance and standardization within the industry when adopting advanced composite materials.

16 TIDAL AND WAVE POWER↗

Environmental Durability Assessment and Development of Subcomponent Test Methods for Advanced Materials in Marine Energy Applications: Preprint

Marine energy developers are beginning to rely more heavily on advanced composite materials for their load bearing structures. Understanding how these materials respond and degrade in harsh marine environments is a complex problem. Much research has been performed at smaller laboratory scales to understand the fundamental physical and chemical degradation mechanisms, but little structural testing research has been performed at larger scales to understand how these physical and chemical interactions scale and how they should be accounted for in the design process. The Advanced Materials project is a multilaboratory research collaboration that has been addressing these issues with the intention of reducing risks and barriers to marine energy developers wanting to adopt advanced composite materials. The National Laboratory of the Rockies has been playing a leading role in developing larger scale testing infrastructure and test methods to validate complex numerical degradation models and standardize testing procedures to do so. This paper provides a review of past structural testing activities and how they have grown into current research activities and will continue to evolve into the future to directly address industry needs. This paper covers key research areas large-scale water absorption and subsequent structural validation testing, qualification of bolted and adhesive connections, and conducting combined submerged fatigue testing at increasing scales. This paper provides insights into the complex requirements for testing infrastructure and test method development to effectively qualify materials and certify marine energy structures for harsh marine environments. This research program paves the way for better guidance and standardization within the industry when adopting advanced composite materials.

16 TIDAL AND WAVE POWER↗

A New Model for Simulating the Imbibition of a Wetting-Phase Fluid in a Matrix-Fracture Dual Connectivity System

The imbibition experiment is an effective approach for measuring petrophysical properties of porous media, with many such experiments performed over the past decade. Quite some empirical, analytical, and numerical models have been developed to simulate spontaneous imbibition of the wetting phase fluid into porous media, but limitations still exist. In previous studies, the imbibition process has been considered to give a piston-like displacement or the porous medium modeled as multiply-sized pores linked with bonds; both approaches fail to yield comprehensive results due to their neglect of the presence of irregular fractures or nonuniform flow paths through the matrix. By building a numerical model for simulating laboratory-scale experimental data, we performed imbibition tests on several fractured Barnett Shale samples having fractures either parallel ( P ) or transverse ( T ) to the bedding plane and used MATLAB to build a new numerical model by combining the imbibition process in fractures and the matrix using concepts from percolation theory. The experimental data show that the rocks with P -direction fractures have a more steady increase of imbibition rates than the case of T -direction one. As the shale matrix with low pore connectivity hampers the upward water movement, the imbibition rate of shales with T -direction fractures will decrease suddenly after the bottom layer in contact with water is saturated during the initial period. This wetting phase movement (WPM) model can simulate 3D porous media with 2D fractures. The rate of imbibition by fractured porous media is associated with physical parameters such as porosity and fracture distribution (e.g., the number and angle of fractures). Using Monte Carlo methods, we examined fracture parameters and predicted elapsed time and cumulative water imbibition, for the Barnett Shale samples. The results show that the rate of imbibed water mass is sensitive to the number of fractures directly connected to water source, and the connectivity between two neighboring grid cells is a key parameter for the wetting-front progression. The findings of this study can help to better understand the imbibition process with multiple influencing processes and factors in fractured-matrix rocks. Although the experiments, data simulation, and prediction results are based only on Barnett Shale samples, the model is readily applicable to imbibition tests of other fractured rocks to show the spatial and temporal behavior during a dynamic imbibition process that are not easily captured experimentally.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Data Curation for Machine Learning Applied to Geothermal Power Plant Operational Data for GOOML: Geothermal Operational Optimization with Machine Learning: Preprint

Geothermal Operational Optimization with Machine Learning (GOOML) is a transferable and extensible component-based geothermal asset modeling framework that considers complex steamfield relationships and identifies optimization prospects using a data-driven approach to physics-guided, data-centric machine learning. This framework has been used to develop digital twins that provide steamfield operators with operational environments to analyze and understand historical and forecasted power production, explore new steamfield configuration possibilities, and seek optimal asset management in real world applications. To create, test, and apply the GOOML framework, diverse time-series datasets spanning multiple years were sourced from various geothermal power plant components within several complex real-world geothermal operations. These operations are based in the United States and New Zealand and include a variety of technologies, end-uses and configurations, collectively covering nearly all relevant operating conditions for modern geothermal fields. Datasets were acquired from multiple sources to ensure that machine learning experiments generalized properly to various operating conditions. It was found that the data varied in quality, format, and completeness. To ensure consistency between the various datasets, a standardized data curation process was developed to reliably streamline data preparation. This paper will discuss best practices as learned from the GOOML data curation process which takes the following steps: 1) acquisition of large quantities of data from power plant operators, 2) digestion of data to gain an initial understanding of what is included, 3) data transformation, which includes converting the data into a standardized machine-readable format so that they can be visualized, quality checked, and cleaned, 4) quality assurance and quality control, involving identification of significant data gaps and apparent anomalies through mapping of data features to real world componentry via the GOOML historical model, followed by discussion with modelers and power plant operators to identify additional data needs and to resolve issues, 5) use in machine learning algorithms, and 6) repetition of steps one through five until all data needs are met and data are deemed suitable for producing trustworthy modeling results which may be disseminated, ideally along with the curated dataset. This iterative process is focused on improving the quality of the data rather than tuning machine learning model parameters and supports a shift towards data-centric AI as a means to improving real-world applicability of geothermal machine learning projects.

access↗

High Temperature Thermal Barrier Coating Evaluation of Yttrium Aluminum Garnet for Gas Turbine Applications

The Solution Precursor Spray Process (SPPS) process has been shown to overcome the durability and property challenges of applying yttrium aluminum garnet (YAG) coating for high temperature thermal barrier coating (TBC) applications (1200°C+) but only limited testing has been performed in representative application environments. In this study, YAG coatings were developed to optimize microstructure and tailor properties for combustion components in an industrial gas turbine. Thermal conductivity, erosion resistance and furnace cycling durability were used to validate YAG properties against the standard yttria-stabilized zirconia coating (YSZ). Graded and multi-layered microstructures were applied to enhance performance while maintaining durability. Further YAG process development was required to replicate coating properties and optimize deposition on more complex fuel injector nozzle and combustion liner components. Rig testing of both components was performed and compared against the baseline YSZ coating validating the high temperature capability and lower thermal conductivity of the SPPS YAG coating. The components in both tests were cycled for a minimum of ten cycles with the fuel injector test targeting a higher operating temperature while the combustor liner operated at standard conditions. A development engine test is planned to further validate performance in a gas turbine engine of this promising material.

36 MATERIALS SCIENCE↗