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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Filling-enforced obstructed atomic insulators

Topological band theory has achieved great success in the high-throughput search for topological band structures both in paramagnetic and magnetic crystal materials. However, a significant proportion of materials are topologically trivial insulators at the Fermi level. In this paper, we show that, remarkably, for a subset of the topologically trivial insulators, knowing only their electron number and the Wyckoff positions of the atoms we can separate them into two groups: the obstructed atomic insulator (OAI) and the atomic insulator (AI). The interesting group, the OAI, have a center of charge not localized on the atoms. Using the theory of topological quantum chemistry, in this work we first derive the necessary and sufficient conditions for a topologically trivial insulator to be a filling enforced obstructed atomic insulator (feOAI) in the 1651 Shubnikov space groups. Remarkably, the filling enforced criteria enable the identification of obstructed atomic bands without knowing the representations of the band structures. Hence, no calculations are needed for the filling enforced criteria, although they are needed to obtain the band gaps. With the help of the Topological Quantum Chemistry website, we have performed a high-throughput search for feOAIs and have found that 957 ICSD entries (638 unique materials) are paramagnetic feOAIs, among which 738 (475) materials have an indirect gap. The metallic obstructed surface states of feOAIs are also showcased by several material examples. Published by the American Physical Society 2024

Materials Science↗
DOE OSTI2020

Sequential versus Simultaneous Aging of EPDM Nuclear Cable Insulation Subjected to Elevated Temperature and Gamma Radiation

Electrical cables are integral to power, control, and instrumentation systems within nuclear power plants (NPPs). Exposure of cable systems within nuclear containment to elevated temperatures and gamma radiation during decades-long operation of NPPs can lead to degradation of cable polymeric insulation. Prediction of nuclear cable insulation degradation is complicated as thermal and radiation stress are not additive. In this work, we explore the relative effects of simultaneous and sequential thermal and gamma irradiation on the aging of ethylene-propylene-diene (EPDM) elastomer insulation to better understand realistic scenarios of cable insulation degradation. Cable insulation samples of EPDM were subjected to up to 320 kGy of gamma radiation at a dose rate of 300 Gy/hr in two heating scenarios: (1) simultaneously aged samples were heated at 150°C during irradiation and (2) sequentially aged samples were heated at 150°C for designated durations followed by corresponding periods of irradiation at ambient temperature. The mass, tensile elongation at break, and carbonyl index were assessed to quantify aging of the polymers. The simultaneous aging scenario was found to the more severe of the two for EPDM insulation degradation.

ethylene-propylene-diene elastomer, EPDM, nuclear ↗
DOE OSTI2021

Application of Principal Component Analysis for the Monitoring of the Aging Process of Nuclear Electrical Cable Insulation

To ensure the safe operation of nuclear power plants (NPPs), it is critical to understand how NPP electrical cable insulation will degrade under different service environments. In this study, various nondestructive examination methods were selected to evaluate degradation of electrical cable insulation after aging. Elongation at break, indenter modulus, relaxation constant, mass change, total color difference, and carbonyl index were collected stepwise on cross-linked polyethylene (XLPE) cable insulations after predetermined exposure intervals. Three different insulation aging scenarios were investigated: 1) simultaneous irradiation and heating at 150°C, 2) heating at 150°C followed by corresponding times of irradiation at ambient temperature, and 3) irradiation at ambient temperature followed by heating at 150°C for the same duration. A constant dose rate of 300 Gy/hr was selected with a total gamma irradiation absorbed dose up to 320 kGy. To gain insight into the long-term performance of NPP electrical cable insulation, principal component analysis (PCA), a data-driven approach, was utilized to identify key indicators of cable insulation degradation. By reducing the dimensionality of the data while retaining degradation information, PCA was used to highlight the changes in the measured properties under gamma irradiation according to total absorbed dose and the different aging scenarios.

Li, Donghui↗
DOE OSTI2021

Using Models to Predict the Hygrothermal Performance of Equipment and Piping Insulation

The development of hygrothermal models began in earnest in the 1990s, with the initial emphasis on the performance of building envelope systems. Numerous large-scale building envelope failures associated with water intrusion drove this development. The physical principles of moisture transfer that apply to building envelopes are equally valid for equipment and piping insulation systems. The main advantage of modeling is that carefully characterized models can predict the long-term hygrothermal performance of any system under different climatic and interior conditions. Thermal insulations are commonly used on outdoor equipment and piping for different applications, such as thermal energy conservation and freeze protection. The insulated equipment usually experiences moisture intrusion due to many factors, such as the duration and frequency of moisture exposure, equipment operating temperature, insulation type, exposure temperature, weather conditions, equipment thermal cycling, and weatherproofing condition. Hygrothermal models have been employed to estimate the moisture pickup of insulated equipment and piping systems, as well as the moisture redistribution and subsequent change in thermal performance as these systems become contaminated with moisture. The hygrothermal model provides insights on the parameters influencing the time of wetness, the lateral redistribution of moisture along the pipe away from the leak, and the ease by which water escapes the insulation/jacketing systems. It has been shown that the moisture leak effect decreases rapidly with distance from the leak and that one- and two-dimensional hygrothermal simulations help to identify solutions to reduce conditions that support corrosion under insulation (CUI).

Shrestha, Som↗
DOE OSTI2021

Transformative Building Envelope Retrofit Using Insulation-Inflatable Walls Assisted by Automation

This work highlights the effort to develop a low-cost envelope retrofit for homes built prior to the implementation of energy conservation measures established by the Department of Energy. Inflatable structures were constructed to conform to the exterior envelope (a corner wall construction with a fenestration was used as a prototype). The structures were then filled with spray polyurethane foam insulation. The flexibility in construction and the ability to fill with spray polyurethane foam insulation were demonstrated. In addition, hygrothermal simulations showed that the installation of these systems does not compromise the moisture durability of uninsulated and insulated building envelopes across eight climate zones from hot humid to subarctic. Preliminary cost estimates, based on retail pricing, of the inflatable retrofit including 3 inches of spray foam insulation (insulation value of approximately R 20) is $\$ 4.25$ per square foot uninstalled. The installed cost was calculated using two labor rates, the labor rate for the installation of a weather resistive barrier and the installation of spray foam insulation. Aggregating those values into one labor rate results in an installed cost between $\$ 11$ and $\$ 28$ per square foot. The low end includes the installation of vinyl siding as the exterior cladding. The higher value includes an exterior stucco finish.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

An Innovative Design of High-Temperature, Sensible Molten Salt Thermal Energy Storage Systems With Geopolymer Insulation

This project aims to mitigate the risks of the current molten salt TES tank designs. The goal is to create a more reliable and cost-effective TES by (1) developing a new material solution for internal thermal insulation and (2) by designing a concrete-based tank structure to eliminate metal-related issues (e.g., corrosion, thermomechanical failure, etc.). Firstly, the project aims to engineer a composite refractory insulation material that possesses sufficient thermal insulation properties without significantly sacrificing the resistance to salt permeation and mechanical strength, which is the major trade-off in traditional refractory insulation design. The primary objective is to perform materials design and optimization of the composite refractory to achieve the required thermal and mechanical properties as suitable internal insulation for molten salt TES. Secondly, the project aims to design a concrete-based TES system with conventional low- cost Portland cement serving as the primary tank structure and the aforementioned composite refractory as the internal thermal insulation and salt containment. The objective is to investigate the technical and economical feasibilities of concrete tanks for high- temperature molten salt storage applications.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermal aging effects on crosslinked polyethylene cable insulation with decabromodiphenyl ether flame retardant alternative

Decabromodiphenyl ether (decaBDE) has been extensively used as a flame retardant in several applications, including nuclear electrical cable insulation. However, decaBDE has been identified as a persistent, bioaccumulative and toxic (PBT) substance, leading to regulatory scrutiny. The Environmental Protection Agency (EPA) published a regulation on January 6, 2021, aimed at phasing out the manufacturing, processing, and distribution of decaBDE. This rule set a compliance deadline of March 8, 2021, for the manufacture and processing of decaBDE, and an extended deadline of January 6, 2023, for specific applications including wire and cable insulation in nuclear power generation facilities. In response to such regulations, RSCC, a major supplier of safety-related electrical cables and associated products to the U.S. nuclear industry updated the formula of their crosslinked polyethylene (XLPE) insulation to replace the historically used decaBDE flame retardant with an acceptable alternative. This change from the previous decaBDE-containing XLPE prompted interest in comparative performance of the two material formulations, especially with respect to characteristics relevant to safety-related function such as thermal and radiation resistance. RSCC graciously provided samples of wire insulated with the decaBDE-containing XLPE formulation and corresponding wire insulated with XLPE of the new formulation, containing a decaBDE alternative. In this work we compare characteristics of the two formulations and a previously produced commercial version of the RSCC decaBDE-containing XLPE insulation subjected to thermal aging at 150 °C and 165 °C. The comparison was focused on mechanical durability, thermal stability in the oxidative environment, and chemical structures. Briefly, • Tensile elongation at break (EAB) results showed loss of mechanical elasticity with longer aging time, as expected. Aging time dependence of EAB did not differ between the decaBDE-containing and decaBDE-alternative samples. • Subtle differences between the two materials can be detected from Fourier-transform infrared spectroscopy (FTIR) absorbance spectra in the range below 1700 cm -1 , are assumed to be related to decomposition of flame retardant additives during thermal aging. • The oxidation induction time (OIT) data seemed to show that the unaged decaBDE-containing XLPE material is more thermally stable than the unaged decaBDE-alternative material, but the discrepancy in OIT decreased with aging time and the OIT values of the two materials became similar starting with the 4 th day of aging at 165 °C. This thermal aging investigation confirmed that the mechanical durability, a key property monitored for cable qualification, was not significantly affected by the modification of the formulation with a decaBDE alternative flame-retardant system in the investigated thermal aging conditions. Further studies on the same sets of materials exposed to thermal and gamma radiation aging would further inform comparison of the materials safety-related function.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Consideration of Decabromodiphenyl Ether Flame Retardant in Thermal and Radiation Aging of Crosslinked Polyethylene Cable Insulation

Decabromodiphenyl ether (decaBDE) has been used as a flame-retardant additive in nuclear-grade electrical cable insulation. However, decaBDE has been identified as a persistent, bioaccumulative and toxic (PBT) substance, leading to regulatory scrutiny. On January 6, 2021, the Environmental Protection Agency (EPA) published a final rule to phase out decaBDE. The 2021 rule set a two-year compliance deadline for “processing and distribution in commerce of decaBDE for use in wire and cable insulation in nuclear power generation facilities.” In recognition of industry concerns following a sudden discontinuation of decaBDE-containing Class 1E wire and cable essential for nuclear power operations and the time needed for qualifying the individual components using the alternative insulation technology, an extended compliance deadline was set in the finalized amendments to the 2021 rule as published by the Environmental Appeals Board on November 12, 2024. The 2024 rule set the compliance deadline for processing and distributing decaBDE-containing wire and cable insulation until the end of the service life of these materials. Since decaBDE has long been relied upon as the flame retardant in one of the most common cross-linked polyethylene (XLPE) nuclear cable insulation formulations, RSCC Firewall III insulation, questions have naturally arisen regarding whether changes in cable performance might be expected for XLPE containing a decaBDE alternative, especially for safety-related cables that must perform their safety function in a design basis event such as a loss of coolant accident.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Mitigation of Galvanic Corrosion in Bolted Joint of AZ31B and Carbon Fiber-Reinforced Composite Using Polymer Insulation

The use of polymer insulation to mitigate galvanic corrosion was examined for bolted joints of AZ31B Mg alloy and carbon fiber-reinforced composite. To assess the corrosion behaviors of bolted joints with and without polymer insulation, solution immersion and salt spray exposure (ASTM B117) tests were conducted, and the corrosion depths and volumes were determined for the joint specimens after the tests. The polymer-insulated bolted joints exhibited much lower corrosion depths and volumes, highlighting the effective mitigation of galvanic corrosion. The reductions of joint strength in the post-corrosion joint specimens were relatively small (up to ~10%) in the polymer-insulated group but greater (up to 90%) in the group with no insulation. Cross-sectional characterization of post-corrosion joints with polymer insulation revealed local pits developed on AZ31B under galvanic influence, indicating that limited galvanic attack (that did not decrease the joining integrity significantly) could still occur during a long salt spray exposure (~1264 h) owing to the permeation of an aqueous corrosive medium.

36 MATERIALS SCIENCE↗
NASA NTRS1978

An ultralightweight, evacuated, load-bearing, high-performance insulation system

A new hollow-glass microsphere insulation and a flexible stainless-steel vacuum jacket were demonstrated on a flight-weight cryogenic test tank, 1.17 m in diameter. The weight of the system is three times lighter than the most advanced vacuum-jacketed design demonstrated to date, a free-standing honeycomb hard shell with a multilayer insulation system (for a Space Tug application). Design characteristics of the flexible vacuum jacket are presented along with a model describing the insulation thermal performance as a function of boundary temperatures and emittance, compressive load on the insulation and insulation gas pressure. Test data are compared with model predictions and with prior flat-plate calorimeter test results. Potential applications for this insulation system or a derivative of this system include the cryogenic Space Tug, the Single-Stage-to-Orbit Space Shuttle, LH2 fueled subsonic and hypersonic aircraft, and LNG applications.

Parmley, R. T.↗
NASA NTRS1981

Defect design of insulation systems for photovoltaic modules

A defect-design approach to sizing electrical insulation systems for terrestrial photovoltaic modules is presented. It consists of gathering voltage-breakdown statistics on various thicknesses of candidate insulation films where, for a designated voltage, module failure probabilities for enumerated thickness and number-of-layer film combinations are calculated. Cost analysis then selects the most economical insulation system. A manufacturing yield problem is solved to exemplify the technique. Results for unaged Mylar suggest using fewer layers of thicker films. Defect design incorporates effects of flaws in optimal insulation system selection, and obviates choosing a tolerable failure rate, since the optimization process accomplishes that. Exposure to weathering and voltage stress reduces the voltage-withstanding capability of module insulation films. Defect design, applied to aged polyester films, promises to yield reliable, cost-optimal insulation systems.

Mon, G. R.↗
NASA NTRS1984

An external insulation system for a cryogenic wind tunnel

The thermal insulation system of the 0.3-Meter Transonic Cryogenic Tunnel (0.3-m TCT) at the NASA Langley Research Center is described in text, photographs, and drawings. The system is designed to operate from room temperature down to about 77.4 K, the temperature of liquid nitrogen at 1 atmosphere. A detailed description is given of the primary insulation system which consists of glass fiber mats, a 3-part vapor barrier, and a dry nitrogen positive-pressure purge system. Also described are several secondary insulation systems required for the test section, actuators, and tunnel supports. An appendix briefly describes the original insulation system which is considered inferior to the one presently in place. Time required for opening and closing portions of the insulation system for modification or repair to the tunnel has been reduced, typically, from a few days for the original thermal insulating system to a few hours for the present system.

Dress, D. A.↗
NASA NTRS1991

The full-scale process and design changes for elimination of insulation edge separations and voids in tang flap area

Qualification of the full-scale process and design changes for elimination of redesigned solid rocket motor tang nitrile butadiene rubber insulation edge separations and voids was performed from 24 March to 3 December 1990. The objectives of this test were: to qualify design and process changes on flight hardware using a tie ply between the redesigned solid rocket motor steel case and the nitrile butadiene rubber insulation over the tang capture features; to qualify the use of methyl ethyl ketone in the tang flap region to reduce voids; and to determine if holes in the separator film reduce voids in the tang flap region. The tie ply is intended to aid insulation flow during the insulation cure process, and thus reduce or eliminate edge unbonds. Methyl ethyl ketone is intended to reduce voids in the tang flap area by providing better tacking characteristics. The perforated film was intended to provide possible vertical breathe paths to reduce voids in the tang area. Tang tie ply testing consisted of 270 deg of the tang circumference using a new layup method and 90 deg of the tang circumference using the current layup methods. Tie ply process success was defined as a reduction of insulation unbonds. Lack of any insulation edge unbonds on the tang area where the new process was used, and the presence of 17 unbonds with the current process, proves the test to be a success. Successful completion of this test has qualified the new processes.

Danforth, Richard A.↗
NASA NTRS1992

ASRM case insulation design and development

This paper describes the achievements made on the Advanced Solid Rocket Motor (ASRM) case insulation design and development program. The ASRM case insulation system described herein protects the metal case and joints from direct radiation and hot gas impingement. Critical failure of solid rocket systems is often traceable to failure of the insulation design. The wide ranging accomplishments included the development of a nonasbestos insulation material for ASRM that replaced the existing Redesigned Solid Rocket Motor (RSRM) asbestos-filled nitrile butadiene rubber (NBR) along with a performance gain of 300 pounds, and improved reliability of all the insulation joint designs, i.e., segmented case joint, case-to-nozzle and case-to-igniter joint. The insulation process development program included the internal stripwinding process. This process advancement allowed Aerojet to match to exceed the capability of other propulsion companies.

Bell, Matthew S.↗
NASA NTRS1999

Cryogenic Insulation System for Soft Vacuum

The development of a cryogenic insulation system for operation under soft vacuum is presented in this paper. Conventional insulation materials for cryogenic applications can be divided into three levels of thermal performance, in terms of apparent thermal conductivity [k-value in milliwatt per meter-kelvin (mW/m-K)]. System k-values below 0.1 can be achieved for multilayer insulation operating at a vacuum level below 1 x 10(exp -4) torr. For fiberglass or powder operating below 1 x 10(exp -3) torr, k-values of about 2 are obtained. For foam and other materials at ambient pressure, k-values around 30 are typical. New industry and aerospace applications require a versatile, robust, low-cost thermal insulation with performance in the intermediate range. The target for the new composite insulation system is a k-value below 4.8 mW/m-K (R-30) at a soft vacuum level (from 1 to 10 torr) and boundary temperatures of approximately 77 and 293 kelvin (K). Many combinations of radiation shields, spacers, and composite materials were tested from high vacuum to ambient pressure using cryostat boiloff methods. Significant improvement over conventional systems in the soft vacuum range was demonstrated. The new layered composite insulation system was also shown to provide key benefits for high vacuum applications as well.

Augustynowicz, S. D.↗
NASA NTRS1999

Use of Several Thermal Analysis Techniques to Study the Cracking of a Nitrile Butadiene Rubber (NBR) Insulator on the Booster Separation Motor (BSM) of the Space Shuttle

Two different vendor rubber formulations have been used to produce the silica-filled NBR insulators for the BSM of each of the two Solid Rocket Boosters (SRBs) on the Space Shuttle. Each cured insulator is bonded to the BSM aluminum aft closure with an epoxy adhesive, and some of the curved areas in the rubber may have significant residual stresses. A number of recently bonded NBR insulators have shown fine surface cracks, and stressed insulator areas may be aging at a faster rate than unstressed areas, thus hastening the surface cracking. Thermal analysis data on both vendor insulators by Dynamic Mechanical Analysis (DMA) through a temperature/frequency sweep from 24 to 74 C have shown a higher flexural storage modulus and Arrhenius activation energy for the stressed area than for the unstressed area. Other thermal analysis techniques are being used to study the insulator surface vs. bulk interior for better understanding this anomaly.

Wingard, Charles D.↗
NASA NTRS2000

Thermal Insulation Performance of Textile Structures for Spacesuit Applications at Martian Pressure and Temperature

Protection of astronauts from the extreme temperatures in the space environment has been provided in the past using multi-layer insulation in ultra-high vacuum environments of low earth orbit and the lunar surface. For planetary environments with residual gas atmospheres such as Mars with ambient pressures between 8 to 14 hPa (8 to 14 mbar), new protection techniques are required because of the dominating effect of the ambient gas on heat loss through the insulation. At Mars ambient pressure levels, the heat loss can be excessive at expected suit external temperatures of 172 K with state-of-the-art suit insulation, requiring an active heat source and its accompanying weight and volume penalties. Micro-fibers have been identified as one potential structure to reduce the heat losses, but existing fundamental data on fiber heat transfer at low pressure is lacking for integrated fabric structures. This baseline study presents insulation performance test data at different pressures and fabric loads for selected polyesters and aramids as a function of fiber density, fiber diameter, fabric density, and fabric construction. A set of trend data of thermal conductivity versus ambient pressure is presented for each fiber and fabric construction design to identify the design effects on thermal conductivity at various ambient pressures, and to select a fiber and fabric design for further development as a suit insulation. The trend data also shows the pressure level at which thermal conductivity approaches a minimum, below which no further improvement is possible for a given fiber and fabric design. The pressure levels and resulting thermal conductivities from the trend data can then be compared to the ambient pressure at a planetary surface, Mars for example, to determine if a particular fiber and fabric design has potential as a suit insulation.

Orndoff, Evelyne↗
NASA NTRS1995

A Network Model for the Effective Thermal Conductivity of Rigid Fibrous Refractory Insulations

A procedure is described for computing the effective thermal conductivity of a rigid fibrous refractory insulation. The insulation is modeled as a 3-dimensional Cartesian network of thermal conductance. The values and volume distributions of the conductance are assigned to reflect the physical properties of the insulation, its constituent fibers, and any permeating gas. The effective thermal conductivity is computed by considering the simultaneous energy transport by solid conduction, gas conduction and radiation through a cubic volume of model insulation; thus the coupling between heat transfer modes is retained (within the simplifications inherent to the model), rather than suppressed by treating these heat transfer modes as independent. The model takes into account insulation composition, density and fiber anisotropy, as well as the geometric and material properties of the constituent fibers. A relatively good agreement, between calculated and experimentally derived thermal conductivity values, is obtained for a variety of rigid fibrous insulations.

Marschall, Jochen↗