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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Multi physics simulation on Reactor Pressure Vessel (RPV) subjected to Pressurized Thermal Shock (PTS) by using Cardinal

The structural components that comprise nuclear reactors and their supporting structures are subjected to harsh operating environments that can challenge their integrity, especially after exposure for extended durations or under accident condition. As one of the most significant components of a Reactor, the Reactor Pressure Vessel (RPV) is exposed to an aggressive environment during the operation time (e.g. more than 40 years). Ageing degradation mechanisms (e.g. thermo-fatigue) could grow initial defects up to a critical size, increasing the susceptibility to failure in the RPV. The conventional methods are mostly based on simple crack and structure geometries. Very limited studies consider the real conditions of the RPV subjected to a thermal shock due to a Loss of Coolant Accident (LOCA). During a LOCA event, the most severe conditions take place when the emergency core cooling (ECC) water is injected inside the cold legs filled initially with hotter water and/or steam. The rapid cooling of the down-comer and the internal RPV surface followed probably by re-pressurization of the RPV causes large temperature gradients and variation of pressure which induces thermal-mechanical stresses. In order to develop the model for integrity assessment of a reactor pressure vessel (RPV) subjected to pressurized thermal shock (PTS), a multi-physics simulation, which includes the thermo-hydraulic, thermo-mechanical and fracture mechanics analyses is necessary.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Combining four-point bending and corrosion to map stress-dependent corrosion susceptibility of 316H stainless steel in FLiNaK

Understanding the effect of stress on the corrosion of steels in molten salts is important for material screening and safety assessment of molten salt reactors. We present a method that combines four-point bending with corrosion testing, enabling the mapping of corrosion susceptibility as a function of local stress from a single specimen. Guided by finite element analysis, a four-point bending setup was used to bend a 316H stainless-steel bar under controlled elastic stress during a 100-hour exposure in FLiNaK at 700 °C. Post-exposure characterization using scanning electron microscopy and energy-dispersive X-ray spectroscopy revealed a pronounced correlation between stress and corrosion. Regions under tensile stress exhibited significantly deeper attack depths and greater chromium depletion along grain boundaries, whereas compressive zones showed shallower corrosion cracks. The stress effect is attributed to stress concentration under tensile loading, which promotes chromium dissolution and crack propagation. This technique can be readily applied to other structural alloys, enabling quantitative measurement of corrosion susceptibility as a function of local stress.

316H↗
NASA NTRS2018

Resolution of a Reflector Shroud Fatigue Failure

Two cracks were observed on a reflector shroud for a space program after previously being subjected to the protoflight test campaign and several regression tests. After extensive analysis and investigations, the failure mechanism was identified to be fatigue as a result of the numerous vibration tests imposed on the unit. Two feasible corrective actions were proposed: first, a notched vibration profile which possesses sufficient margin from the anticipated acoustic and launch loads, while maintaining adequate fatigue life through launch and on-orbit operations, and second, a re-design of the shroud to strengthen the fatigue-susceptible areas. In this paper, we present the inspections, testing, and analysis performed to establish that the cracks were a result of fatigue failure. We discuss the conservative fatigue analysis methodology used in the development of both corrective action options. Finally, we review the lessons learned and the actions incorporated into the rework, subsequent regression testing, and the test plans to minimize the risk of recurrence in future units.

response limiting↗
NASA NTRS1977

Gaseous hydrogen embrittlement of high strength steels

The effects of temperature, hydrogen pressure, stress intensity, and yield strength on the kinetics of gaseous hydrogen assisted crack propagation in 18Ni maraging steels were investigated experimentally. It was found that crack growth rate as a function of stress intensity was characterized by an apparent threshold for crack growth, a stage where the growth rate increased sharply, and a stage where the growth rate was unchanged over a significant range of stress intensity. Cracking proceeded on load application with little or no detectable incubation period. Gaseous hydrogen embrittlement susceptibility increased with increasing yield strength.

Gangloff, R. P.↗
NASA NTRS1990

Damage states in laminated composite three-point bend specimens: An experimental-analytical correlation study

Damage states in laminated composites were studied by considering the model problem of a laminated beam subjected to three-point bending. A combination of experimental and theoretical research techniques was used to correlate the experimental results with the analytical stress distributions. The analytical solution procedure was based on the stress formulation approach of the mathematical theory of elasticity. The solution procedure is capable of calculating the ply-level stresses and beam displacements for any laminated beam of finite length using the generalized plane deformation or plane stress state assumption. Prior to conducting the experimental phase, the results from preliminary analyses were examined. Significant effects in the ply-level stress distributions were seen depending on the fiber orientation, aspect ratio, and whether or not a grouped or interspersed stacking sequence was used. The experimental investigation was conducted to determine the different damage modes in laminated three-point bend specimens. The test matrix consisted of three-point bend specimens of 0 deg unidirectional, cross-ply, and quasi-isotropic stacking sequences. The dependence of the damage initiation loads and ultimate failure loads were studied, and their relation to damage susceptibility and damage tolerance of the mean configuration was discussed. Damage modes were identified by visual inspection of the damaged specimens using an optical microscope. The four fundamental damage mechanisms identified were delaminations, matrix cracking, fiber breakage, and crushing. The correlation study between the experimental results and the analytical results were performed for the midspan deflection, indentation, damage modes, and damage susceptibility.

Starbuck, J. Michael↗
DOE OSTI2025

Assessment of irradiation embrittlement effect on fatigue life of a pressurized-water reactor pressure vessel using the fracture toughness master curve approach

The reactor pressure vessel (RPV) is a critical structural component in pressurized-water reactors, and it is designed to withstand extreme conditions, such as high pressures, elevated temperatures, and prolonged radiation exposure. Ensuring RPV integrity is essential for the safe and reliable long-term operation of nuclear power plants, especially as aging mechanisms such as fatigue and irradiation embrittlement pose increased risks. Fatigue, caused by cyclic thermal and mechanical loading, can lead to crack initiation in localized high-stress regions. Simultaneously, neutron irradiation, particularly in the beltline region, progressively reduces fracture toughness, increasing susceptibility to brittle fracture. These combined effects of fatigue and irradiation embrittlement potentially impact the RPV structural integrity, necessitating fitness-for-service assessments. This study applies the fracture toughness master curve approach to evaluate the impact of irradiation embrittlement on RPV fatigue life. A coupled thermo-mechanical stress analysis identifies critical stress locations under normal service transients, pinpointing regions most vulnerable to fatigue crack initiation and growth. Stress intensity factors for postulated flaws at these locations are calculated, enabling an assessment of fatigue life under irradiated and unirradiated conditions. The results indicate that neutron irradiation embrittlement accelerates the conditions in which a critical crack can form and lead to failure, particularly at lower temperatures. The failure occurs where reduced fracture toughness limits the material’s resistance to crack growth. Axial cracks at nozzle corners are the most life limiting without irradiation, while circumferential cracks demonstrate longer fatigue lives. The findings highlight the importance of incorporating irradiation effects into fatigue life predictions to ensure the long-term structural integrity of RPVs.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Intergranular corrosion of Ni-30Cr in high-temperature hydrogenated water after removing surface passivating film

Abstract High-resolution transmission electron microscopy and atom probe tomography are used to characterize the initial passivation and subsequent intergranular corrosion of degraded grain boundaries in a model Ni-30Cr alloy exposed to 360 °C hydrogenated water. Upon initial exposure for 1000 h, the alloy surface directly above the grain boundary forms a thin passivating film of Cr 2 O 3 , protecting the underlying grain boundary from intergranular corrosion. However, the metal grain boundary experiences severe Cr depletion and grain boundary migration during this initial exposure. To understand how Cr depletion affects further corrosion, the local protective film was sputtered away using a glancing angle focused ion beam. Upon further exposure, the surface fails to repassivate, and intergranular corrosion is observed through the Cr-depleted region. Through this combination of high-resolution microscopy and localized passive film removal, we show that, although high-Cr alloys are resistant to intergranular attack and stress corrosion cracking, degradation-induced changes in the underlying metal at grain boundaries make the material more susceptible once the initial passive film is breached.

(S)TEM↗
NASA NTRS1998

A New Approach to Overcoming Spatial Aliasing in Structural Damage Detection

Aircraft, reusable launch vehicles,unmanned aircraft, and other advanced structures are being built using lightweight composite materials/metals with design safety factors as low as 1.25. These advanced structures operate in uncertain and severe environments and are susceptible to damage such as delamination, fiber/matrix damage, hydrothermal strain in composite materials, and fatigue and cracking in metals. To ensure human safety and load-bearing integrity these structures must be inspected to detect and locate often invisible damage and faults before they become catastrophic. Conventional methods of non-destructive evaluation sometimes miss significant damage and are time consuming and expensive to perform. In contrast, vibrometry or vibration signature techniques are a global method of structural integrity monitoring that potentially can efficiently detect damage on large structures, including damage that is away from sensor locations, and in the interior of structures. However, a barrier problem in damage detection using vibration measurements is the need to measure the vibration response at a large number of points on the structure. Typically, model reduction or expansion procedures such as Guyan reduction or dynamic expansion are attempted to overcome the problem of insufficient measurements or spatial aliasing. These approaches depend on using information from the healthy model, and thus put error into the reduction used to represent the damaged structure. In this paper, a Frequency Response Function technique is used to detect damage to a fixed-free beam. The technique uses measured frequency response functions from the healthy structure as reference data, and then monitors vibration measurements during the life of the structure to detect damage. In an analytical simulation using a finite-element model of a beam, damage was located using only sparse measurements because the technique uses both rotation and translation measurements from the damaged structure.

Schulz, Mark J.↗
DOE OSTI2020

Vibro-acoustic modulation and data fusion for localizing alkali–silica reaction–induced damage in concrete

This article investigates the application of vibro-acoustic modulation testing for diagnosing damage in concrete structures. The vibro-acoustic modulation technique employs two excitation frequencies on a structure. The interaction of these excitations in the measured response indicates damage through the presence of sidebands in the frequency spectra. Past studies using this technique have mostly focused on metals and composites (thin plates or laminates). Our research focuses on concrete, which is a highly heterogeneous material susceptible to a variety of chemical, physical, and mechanical damage processes. In particular, this article investigates diagnosing cracking in concrete from an expansive gel produced by an alkali–silica reaction in the presence of moisture. Past studies have been limited to damage detection using vibro-acoustic modulation testing, whereas this article extends the technique to damage localization. A cement slab with pockets of reactive aggregate is used to investigate the diagnosis technique. The effects of different testing parameters, such as locations, magnitudes, and frequencies of the two excitations, are analyzed and incorporated in the damage localization methodology. A Bayesian probabilistic methodology is developed to fuse the information from multiple test configurations in order to construct damage probability maps for the test specimen. The results of vibro-acoustic modulation–based damage localization are validated by petrographic study of cores taken from the slab.

Karve, Pranav↗
NASA NTRS1979

Stresses from arbitrary loads on a circular crack

An inclusive theory is developed for stresses and displacements due to arbitrarily distributed normal and tangential loads acting on a circular crack in an infinite body. The representation chosen for the boundary conditions leads to solutions expressed as series of Bessel-function integrals of a class quite susceptible to further analysis and to rapid evaluation on modern computers. The load coefficients which appear in all the solution series bear intelligible interpretation, and stress intensity factors are related to them by simple formulas. The inclusiveness and tractability of the solutions qualify this theory to be a useful part of analyses for cracks in finite bodies in which the effective crack loads can assume many patterns.

Bell, J. C.↗
DOE OSTI2025

Experimental Validation of a Module Cell Cracking Model

The What's Cracking app can predict how changes in crystalline silicon photovoltaic (PV) module materials, design, and mounting affect its susceptibility for cell fracture under uniform loading. This work has experimentally validated the app. A set of commercial crystalline silicon PV modules was obtained for this study. The modules were uniformly loaded at three different mounting points, and their subsequent cell fractures were recorded. A large sample size allowed for the development of an experimental statistical model for cell fracture. Here, the comparison of the experiment to predictions from the app is in excellent agreement. Both experimental and modeling results also elucidate how moving the module mounting points toward the center of the module increases the probability of cell fracture.

14 SOLAR ENERGY↗
NASA NTRS2016

Below-Ambient and Cryogenic Thermal Testing

Thermal insulation systems operating in below-ambient temperature conditions are inherently susceptible to moisture intrusion and vapor drive toward the cold side. The subsequent effects may include condensation, icing, cracking, corrosion, and other problems. Methods and apparatus for real-world thermal performance testing of below-ambient systems have been developed based on cryogenic boiloff calorimetry. New ASTM International standards on cryogenic testing and their extension to future standards for below-ambient testing of pipe insulation are reviewed.

below-ambient↗
DOE OSTI2020

Role of Material Condition in Precursor Corrosion Damage and Stress Corrosion Crack Initiation Behavior of Alloy 600 in PWR Primary Water

Stress corrosion crack (SCC) initiation testing has been performed on a 15% cold-worked UNS N06600 (Alloy 600) heat in the mill-annealed (MA), solution annealed (SA), and thermally treated (TT) conditions to assess the role of grain boundary (GB) carbides on stress-assisted intergranular attack (IGA) and short crack nucleation and growth. The SCC initiation tests were conducted at constant load equivalent to materials yield stress in 360oC simulated PWR primary water with dissolved hydrogen at the Ni/NiO stability line. Results revealed the highest SCC initiation susceptibility in the Alloy 600 MA material followed by the TT and SA materials, suggesting the GB carbide distribution did not have a controlling effect on SCC initiation resistance. Quantitative assessments were conducted on IGA and short cracks to help understand this phenomenon and the role of GB carbides on precursor damage development that lead to differences in macroscopic SCC initiation behavior are discussed.

Zhai, Ziqing↗
NASA NTRS1972

Effect of initial hydrogen content of a titanium alloy on susceptibility to hot salt stress corrosion.

The influence of the initial hydrogen content of a titanium alloy on subsequent resistance to hot salt stress corrosion embrittlement and cracking was investigated. A Ti-8Al-1Mo-1V alloy was tested in four conditions: mill annealed (70 ppm H), duplex annealed (70 ppm H), vacuum annealed to an intermediate (36 ppm H) and a low (9 ppm H) hydrogen level. Material annealed at 650 C (duplex condition) exhibited resistance to hot salt stress corrosion superior to that exhibited by material in the mill annealed condition. Reduction of the alloy hydrogen content from 70 to as low as 9 ppm did not influence resistance to hot salt stress corrosion embrittlement or cracking.

Gray, H. R.↗
DOE OSTI2023

Refinement of Pitting Factor Basis to Support the Corrosion Control Program (Interim Report)

At Savannah River Site (SRS), High-Level Waste is stored in below-grade tanks constructed of carbon steel. This waste is composed of sludge, salt cake, and/or supernate. In part, preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to a number of corrosion processes. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion or stress corrosion cracking (SCC) of carbon steel. Additionally, during the salt dissolution process, in the absence of mixing, stratification of the supernatant liquid may occur. This can result in less dense, more dilute waste layers occurring higher in the tank. In these more dilute waste layers, the susceptibility to localized corrosion could potentially differ from that of the more concentrated salt solutions evaluated in previous testing, as the amount of inhibiting and aggressive species, not just the ratios, can affect susceptibility. Evaluation of the susceptibility to localized corrosion in these more dilute waste chemistries could provide insight into the amount of inhibitors required to effectively mitigate pitting corrosion in stagnant salt dissolution environments, as well as other tank farm operations involving dilute waste streams.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

OVERVIEW OF PARTICLE DEPOSITION MODELS FOR SPENT NUCLEAR FUEL STORAGE SYSTEMS

Deposition models were built to evaluate contaminant deposition on spent nuclear fuel (SNF) canisters. The primary contaminant of concern is chloride, which is dispersed in the atmosphere and then deposits onto the canisters. During dry storage, the primary degradation process is likely to be Chloride Induced Stress Corrosion Cracking (CISCC) at the heat-affected zones of the canister welds. It is known that stainless steel canisters are susceptible to CISCC; however, the rate of chloride deposition onto the canisters is poorly known, based on sparse field data from a small number of sites. The models presented in this study could be useful for determining the rate of deposition on the canisters and the likelihood of CISCC to help with SNF canister ageing management. The deposition models were developed with the commercial computational fluid dynamics (CFD) code STAR-CCM+. Various deposition mechanisms were considered and incorporated into the models, and a sensitivity study was conducted to determine the most important mechanisms for deposition within a SNF storage system. The models included both a vertical and horizontal configuration storage system: NAC International’s Modular, Advanced Generation, Nuclear All-purpose STORage System (MAGNASTOR®) and a NUHOMS® horizontal storage module respectively. The resulting canister deposition on the horizontal canister is visually compared with inspection data taken onsite at the Calvert Cliffs Nuclear Power Plant. These models are preliminary, and development of the models will continue. Future validation exercises are currently being planned, including the Canister Deposition Field Demonstration (CDFD) effort funded by U.S. Department of Energy office of Nuclear Energy office of Spent Fuel Waste Science and Technology. The goal of the modeling presented is to demonstrate a potential modeling technique that could be used to plan and inform SNF canister ageing management programs with predictive models for the timing and occurrence of canister CISCC.

Suffield, Sarah R.↗
NASA NTRS1987

Noble Metals Would Prevent Hydrogen Embrittlement

According to proposal, addition of small amounts of noble metals makes iron- and nickel-based alloys less susceptible to embrittlement by hydrogen. Metallurgists demonstrated adding 0.6 to 1.0 percent by weight of Pd or Pt eliminates stress/corrosion cracking in type 4130 steel. Proposal based on assumption that similar levels (0.5 to 1.0 weight percent) of same elements effective against hydrogen embrittlement.

Paton, N. E.↗