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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development of Surveillance Test Articles for Materials Degradation Management in MSR Environments

Materials in molten salt reactors (MSR) undergo accelerated degradation from corrosion, irradiation, and cyclic loads at elevated temperatures. Establishing a materials surveillance program to enable the assessment of material deterioration is critical to assure structural integrity of MSRs components. This presentation summarizes recent efforts towards the development of surveillance test articles for collecting various damages for monitoring materials degradation. Surveillance test articles with reduced dimensions were designed to capture creep-fatigue damage from cyclic loading at elevated temperatures. The strain evolution of test articles during thermal cycling was analyzed both numerically and experimentally. Out-of-reactor thermal cycling demonstrated successful capture of strain range for materials assessment. Moreover, test articles were subject to both mechanical loads and molten salt exposure, and the damage due to stress and corrosion was investigated. Additionally, damage inference models were developed to predict the remaining life of materials based on the accumulated damage in surveillance test articles.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

A semi-coupled aero-servo-hydro numerical model for floating vertical axis wind turbines operating on TLPs

Floating vertical axis wind turbines (VAWTs) have many advantages over floating horizontal axis wind turbines (HAWTs) at large scales in deep water; however, there are several key challenges to overcome as well. One of the challenges is accurate prediction of the dynamic motion and loads performance of a floating VAWT. Here, a new semi-coupled aero-servo-hydro method is developed to assess dynamic responses of a floating VAWT by modeling the system as a 7-degree-of-freedom (7-DOF) model: the supporting platform is considered as a 6-DOF rigid body; the rotation of the rotor is considered as the 7th DOF. Aerodynamic, hydrodynamic, and mooring loads and control of the rotor speed are fully considered. This model can predict performance of floating VAWTs with reasonable fidelity according to validation with OrcaFlex through static and dynamic responses of a floating VAWT with Darrieus rotor operating on a new tension-leg platform (TLP). Being a reduced complexity model, the 7-DOF model can be efficiently applied to assess performance of the newly designed floating VAWT. This model is used to examine the relative contributions of aerodynamic and wave loads imparted to the floating system and the benefits of a three-bladed VAWT over a two-bladed VAWT through dynamic and fatigue analysis.

17 WIND ENERGY↗
DOE OSTI2024

Endowing low fatigue for elastocaloric effect by refined hierarchical microcomposite in additive manufactured NiTiCuCo alloy

Abstract NiTiCu-based shape memory alloys have been considered as ideal materials for solid-state refrigeration due to their superb cycling stability for elastocaloric effect. However, the embrittlement and deterioration caused by secondary phase and coarse grains restrict their applications, and it is still challenging since the geometric components are required. Here, bulk NiTiCuCo parts with excellent forming quality were fabricated by laser powder bed fusion (LPBF) technique. The as-fabricated alloy exhibits refined three-phases hierarchical microcomposite formed based on the rapid cooling mode of LPBF, composed of intricate dendritic Ti 2 Ni–NiTi composite and nano Ti 2 Cu embedded inside the NiTi-matrix. This configuration endows far superior elastocaloric stability compared to the as-cast counterpart. The low fatigue stems from the strong elastic coupling between the interphases with reversible martensite transformation, revealed byin-situsynchrotron high-energy x-ray diffraction. The fabrication of NiTiCuCo alloy via LPBF fills the bill of complex geometric structures for elastocaloric NiTiCu alloys. The understanding of interphase micro-coupling could provide the guide for designing LPBF fabricated shape memory-based composites, enabling their applications for special demands on other functionalities.

Engineering↗
DOE OSTI2023

A Hybrid Physics-Based, Data-Driven Approach to Model Damage Accumulation in Corrosion of Polymeric Adhesives

The degradation of polymeric adhesives in dissimilar joints is a menace to electric and structural components of the automotive industry. In polymeric adhesives, failure often occurs due to damage accumulated from discrete environmental sources—thermal degradation, oxidation, hydrolysis, radiation, and moisture—that are combined with progressive damage mechanisms, such as aging and fatigue. Because most damage mechanisms that lead to degradation act in parallel, the estimation of the lifetime of a polymeric material becomes a significant reliability issue, no study currently exists that can simultaneously consider even two of these phenomena. Most current efforts are directed toward a single-phenomenon, single-model approach in which a model is developed to cover one specific damage mechanism. While this approach is advantageous in exploring single mechanisms, it is strongly inconclusive for degradation that occurs by multiple damage mechanisms. Our team plans to take a fresh perspective by designing a hybrid constitutive/data-driven approach that allows models of different damage mechanisms to be integrated into one model and then used to explore the degradation-induced failure of polymeric adhesives. The theoretical-computational part of this work is divided into four research components as described in the Approach section below.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Preliminary Plan to Inform Testing of a Heat Exchanger Test Article

This report presents a preliminary plan to guide the qualification testing of advanced heat exchanger (HX) components for nuclear-to-industrial heat transfer applications. The objective is to establish a defensible, physics-based methodology that integrates computational modeling, targeted experimentation, and in-service inspection considerations to demonstrate component performance and reliability under representative reactor conditions. The analysis identifies Sodium-cooled Fast Reactor (SFR) and High-Temperature Gas-cooled Reactor (HTGR) systems as reference configurations in terms of temperature, pressure, and chemical environment. Within these operating envelopes, dominant degradation mechanisms— including creep–fatigue interaction, flow-induced vibration, corrosion, and diffusion-bond deterioration—were evaluated to define test requirements. A comprehensive computationalexperimental framework is proposed to support life prediction and qualification activities. The framework couples high-fidelity structural-mechanics, thermal-hydraulic, and fluid-structure interaction models with accelerated degradation testing to produce a traceable linkage between microstructural evolution, mechanical performance, and remaining useful life (RUL). The approach adheres to established Verification, Validation, and Uncertainty Quantification (VVUQ) standards (ASME V&V 10/20; NUREG-2152) and incorporates a digital-twin architecture for continuous model refinement through data assimilation. The plan further outlines testing methodologies, including pre-test analyses, test-loop design parameters, and sensor placement strategies that maximize information yield while maintaining mechanistic fidelity. Complementary sections describe in-service inspection (ISI), on-line monitoring (OLM), and structural-health-monitoring (SHM) techniques applicable to compact HX geometries typical of advanced reactors. Collectively, these activities establish the technical foundation for demonstrating 40-60-year equivalent service life of advanced heat exchangers in support of the U.S. Department of Energy’s Advanced Reactor and Integrated Energy Systems programs. The forthcoming phase will execute the defined pre-test analyses, initiate hardware fabrication, and implement the integrated testing campaign to validate the proposed qualification methodology.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Phase Transformation Driven by Oxygen Vacancy Redistribution as the Mechanism of Ferroelectric Hf 0.5 Zr 0.5 O 2 Fatigue

As a promising candidate for nonvolatile memory devices, the hafnia-based ferroelectric system has recently been a hot research topic. Although significant progress has been made over the past decade, the endurance problem is still an obstacle to its final application. In perovskite-based ferroelectrics, such as the well-studied Pb[Zr x Ti 1-x ]O 3 (PZT) family, polarization fatigue has been discussed within the framework of the interaction of charged defects (such as oxygen vacancies) with the moving domains during the switching process, particularly at the electrode-ferroelectric interface. Armed with this background, a hypothesis is set out to test that a similar mechanism can be in play with the hafnia-based ferroelectrics. The conducting perovskite La-Sr-Mn-O is used as the contact electrode to create La 0.67 Sr 0.33 MnO 3 / Hf 0.5 Zr 0.5 O 2 (HZO)/ La 0.67 Sr 0.33 MnO 3 capacitor structures deposited on SrTiO 3 -Si substrates. Nanoscale X-ray diffraction is performed on single capacitors, and a structural phase transition from polar o-phase toward non-polar m-phase is demonstrated during the bipolar switching process. The energy landscape of multiphase HZO has been calculated at varying oxygen vacancy concentrations. Based on both theoretical and experimental results, it is found that a polar to non-polar phase transformation caused by oxygen vacancy redistribution during electric cycling is a likely explanation for fatigue in HZO.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Development and Verification of an Improved Wake-Added Turbulence Model in FAST.Farm

We introduce a generalized wake-added turbulence (WAT) model in the multiphysics, multiturbine simulation tool FAST.Farm. The WAT model introduces additional small-scale turbulence that represents the breakdown of vortical structures and shear layers in the wake. The article describes the development, implementation, calibration, and verification of the model. The novelties of the model include support for wake asymmetry, buildup of WAT across the wind farm, and secondary effects of wake-induced turbulence (e.g., wake meandering) driven by smaller-scale turbulence structures that arise from wake breakdown. Large-eddy simulations were run to support the calibration of the WAT parameters and verification of the model. Previous studies hypothesized that the lack of WAT modeling was the source of underprediction of fatigue loads, in particular for cases at low turbulence intensities and/or stable atmospheric boundary layers. This study confirms that the newly implemented WAT model enhances the loads predictions in these cases.

17 WIND ENERGY↗
DOE OSTI2022

Nitinol Electroslag Remelting: Initial Slag Study

Nitinol’s unique shape memory and super-elastic properties make it attractive for many applications in biomedical, automotive, aerospace, industrial refrigeration, and waste heat reclamation industries. The fatigue performance is limited however, by non-metallic inclusions (NMI) formed during the traditional VIM/VAR or multi-VAR process. ESR is a potential alternative melt process and is commonly used to refine ingot chemistry and enhance the metallurgical structure of many superalloys and specialty steels, but no study on ESR of Nitinol has been reported to date. The key to establishing a successful ESR process is selecting a compatible slag. In this study, several different slag chemistries are evaluated for their compatibility with Nitinol. One slag chemistry is chosen, along with a control, to produce four Nitinol ESR ingots. Pursuit of a novel slag chemistry for adequate Nitinol refinement is discussed.

Fezi, Kyle↗
DOE OSTI2025

VitriEdge: Repairable & Durable Vitrimer Coatings for Wind Turbine Blade Leading Edges

The primary goal of this Level 1b incubator project was to explore the use of vitrimer coatings for repair of leading-edge erosion on end-of-life wind turbine blade surfaces, beyond coating strength of adhesion which has previously been demonstrated in the Level 1a project. Uniform vitrimer coatings (thickness: 400 µm) were applied to two end-of-life wind turbine blades for flexural, fatigue, and laminate tensile testing where the addition of the coating did not produce any statistical variation in tensile properties with minor drops in flexural strength for some laminate formulations. However, a <2% variation in storage modulus was measured for laminate structures (i.e., blade samples with vitrimer coatings) across 100,000 flexural cycles and upon laminate tensile failure, the vitrimer coatings displayed no visible signs of delamination. In addition, three methods to heal vitrimer coating damage was displayed: oven heating, addition of hot water, and a forced convection heat gun. All three heating and healing mechanisms demonstrated significant healing with scratch depths decreasing between 79-91% at healing times ranging between 1-min and 10-minutes. Finally, a water jet machine was used to simulate rain erosion for both the blade surfaces and vitrimer-coated blade surfaces where the diameter and depth of the damage was recorded as a function of exposure time, water pressure, height of exposure, and angle of exposure. Of interest, while the vitrimer coating did not significantly lessen the damage experienced during rain erosion, the addition of vitrimer composite coatings(5 wt.% mica addition) did result in a crack-resistant, durable coating capable of self-healing behavior and in all cases the angle of rain exposure was the most critical parameter explored. It is crucial to continue exploring this space where vitrimer coatings are of interest for both their self-healing properties and potential use as reversible adhesives.

17 WIND ENERGY↗
DOE OSTI2020

An Initial Assessment of the Design Margins of Different ASME Section III, Division 5 Design Rules

This report develops a method for assessing the design margin of the ASME Section III, Division 5 Class A design rules, focusing on a definition of margin as the ratio between the actual, expected component life and the ASME design life. Full inelastic finite element simulations with a complete damage model capturing the available creep, creep-fatigue, fatigue, and tension test failure data produce the expected component lives, which can then be compared to corresponding ASME design calculations. The focus of this particular work is on Alloy 617 and the ASME creep-fatigue design rules, but the approach is general and could be applied to other design limits and to other materials. A margin assessment of a representative Alloy 617 component shows the ASME creep-fatigue design rules applied to this component have a margin of 10 on design life. The report describes several challenges in completing a more comprehensive margin assessment of the ASME rules, in particular challenges in developing probabilistic assessment methods for high temperature structural components. The report details these challenge and discusses the immediate possibilities of the deterministic margin assessment method developed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Offshore Wind Turbine Blade (85 to120meters ultra-long blade) static and fatigue test

Offshore blades are not just longer, they are wider, heavier and more flexible. These longer blades are a key component of larger wind turbines and for turbines to be more efficient in low wind speeds. These longer blades help reduce the LCOE further and make offshore wind even more competitive. As described earlier, it is essential for the blades to be fully tested to verify and validate the blade designs and manufacturing processes to ensure a reliable product is installed in the field. Through this project WTTC developed and procured new testing equipment required to test longer blades with larger deflections and higher loads. R&D’s BCDA system commissioned was the largest fatigue test exciter system in the world and set the bar for other blade testing facilities worldwide.

17 WIND ENERGY↗
DOE OSTI2024

On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures

Laser Powder Directed Energy Deposition (LP-DED) can produce thin-wall features on the order of 1 mm. These features are essential for large structures operating in extreme environments such as regeneratively cooled nozzles and heat exchangers, which often make use of refractory metals. In this work, the mechanical behavior of LP-DED C103 was investigated via quasi-static tensile testing and low cycle fatigue (LCF) testing. The effects of vacuum stress relief (SR) and hot isostatic pressing (HIP) heat treatments were investigated for specimens in the vertical and horizontal build orientations during tensile testing. The AB and SR properties were lower than literature values for wrought and laser powder bed fusion (L-PBF) bulk components but higher than electron beam powder bed fusion (EB-PBF). The application of a HIP cycle improved strength by 7% and ductility by 27% past the initial as-built condition. Fracture images reveal that interlayer stress concentration sites are responsible for fracture in specimens in the vertical orientation. Meanwhile, fracture in the horizontal specimens mainly propagates at a slanted angle typical of plane stress conditions. The LCF results show cycles to failure ranging from 100 cycles to 8000 cycles for max strain levels of 2% and 0.5%, respectively. Fractography on the fatigue specimens reveals an increasing propagation zone as max strain levels are increased. The impact of these findings and future work are discussed in detail.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Measure Effects of Molten Halide Salt on Creep Rupture Lifetime for 316H, 709 and 617

Ongoing commercialization of different molten salt reactor concepts can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy in molten fluoride salt. This task evaluated the creep behavior of candidate structural materials 316H, 709 and 617 for advanced nuclear reactors under molten halide salt environments at 650, 700 and 750°C respectively. Creep tests were conducted in air, Ar, fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts. The molten salt environment caused a 50% reduction in creep rupture lifetime for 316H in FLiNaK and an 80% reduction in creep rupture lifetime in NaCl-MgCl 2 compared to air exposures. The molten fluoride salt environment resulted in almost a 90% and 50% reduction in creep rupture time for 709 and 617 irrespective of the cover gas environment (air and Ar). Significant differences in the compositional changes between the salt- and air-facing surfaces were observed in the alloy subsurface which might have potentially lead to formation of phases detrimental to the creep behavior.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Physics-based Multiscale Additively Manufactured Superalloy Design for Optimized High Cycle Fatigue Life (Final Report)

The objectives of this project are to: (i) Gain fundamental understandings towards the microscopic damage mechanisms, as impacted by pertinent materials properties (e.g. stacking fault energy (SFE) and microstructure (e.g., grain size), leading to high-cycle fatigue (HCF) damage to AM Ni-based superalloy parts; (ii) Provide scientific insight into the effect of testing frequency on damage mechanisms and fatigue life of AM Ni-based superalloy parts under HCF regime, thereby establishing an appropriate correlation between accelerated testing and materials’ true service life; (iii) Devise an accurate, experimentally validated multiscale model across atomic, micro- and meso-scales, to predict the cyclic stress-strain responses and fatigue damage accumulation for AM Ni-based superalloys under various loading frequencies.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part II—Design Rules

The challenge of using existing ASME Section III, Division 5, class A metallic materials for the construction of structural components of advanced reactors with corrosive coolants could be mitigated by allowing designers to use cladding to protect the base material from corrosion. However, the existing Section III, Division 5 rules provide no guidance on the evaluation of strain accumulation and creep-fatigue damage in cladded components. The availability of design rules for cladded components that do not require long-term clad material testing could promote the application of the cladding approach to accelerate the deployment schedule of these advanced reactor systems. To avoid long-term properties for the clad materials Part I of this work proposes two approximate design analysis methods for two types of clad materials—soft clads that creep much faster and have lower yield stress than the class A base material, and hard clads that creep much slower and have higher yield stress than the class A base material. The proposed analysis methods approximate the response of a soft clad by treating it as perfectly compliant and of a hard clad by treating it as linear elastic. Based on these approximate design analysis strategies this Part II develops a complete set of design rules for class A components cladded with either soft or hard clad materials. In conclusion, Part II discusses the reasoning behind the proposed design rules and uses example finite element analyses of representative reactor components to illustrate the use of these design methods.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Transportation analysis and related design optimization of the Fermilab high-beta 650 MHz cryomodule

The Proton Improvement Plan-II (PIP-II) at Fermi National Accelerator Laboratory (FNAL) will create a new and vastly improved accelerator, which will be the source of high-energy particles for the experiments taking place at FNAL. The new linear accelerator (LINAC) contains several types of cryomodules, which are individual particle accelerators. The last cryomodule in the LINAC will be the High-Beta 650 (HB650), which will operate at 650 MHz. Each module is approximately 15 meters in length and 1.5 meters wide, weighs 13 tonnes, and shares many design features with three of the other cryomodules. The HB650 consists of two primary sections, the outer vacuum vessel and the components that reside within it, which will be cooled to cryogenic temperatures – the cold mass. Once assembly is complete at FNAL, it will be transported to one of three places: another location at FNAL, another national laboratory within the continental United States, or to a scientific partner in Europe. Any excitation the module experiences, such as going over rough roads when on a semitrailer, can create high stresses in components and cause failure if severe enough. Additionally, any delicate components with low resonant frequencies that match the excitation spectrum could achieve resonance, potentially causing a fatigue failure by repeated flexing. To ensure the successful transportation of the HB650, a transport analysis utilizing ANSYS simulation software has been performed on major subassemblies, as well as analysis of the subassemblies as a combined system. The optimization of components, design of support structures, and overall increasing of the lowest resonant frequencies have resulted in a cryomodule that will be better equipped to handle transportation and any large impact loads that come with it.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Fitness-for-Service Analysis of Reactor Components under Flexible Load-Following Operating Conditions

Conventional power-generation plants, including nuclear plants, have been traditionally designed to provide a steady baseload energy capacity, optimizing output efficiency while minimizing variable costs. However, the growing adoption of large-scale renewable energy-generation systems, which rely on intermittent sources such as solar and wind, has introduced more variability into the energy supply in interconnected electricity grids. As a result, the next generation of power plants needs to operate in what is known as the load-following mode, requiring flexible adjustments in electricity production to align with the energy demand on the grid. This transition from the steady baseload operation to load-following operating conditions can significantly increase the number of times various plant components are exposed to transient stresses. This increased thermo-mechanical cycling can lead to accelerated material degradation, thereby elevating the risk of premature failure of a component. It becomes imperative to conduct a comprehensive analysis of fatigue, creep-fatigue, and stress corrosion cracking life, to assess the resilience of the various engineering components under these flexible load-following operating conditions. This study aims to develop a comprehensive numerical model of a light-water reactor pressure vessel (RPV) to investigate its degradation under various operating scenarios. This coupled thermo-mechanical finite element analysis evaluated the stress response of the RPV caused by considering fluctuations in thermal and mechanical loads caused by the varying pressure and temperature occurring during the load-following operation. Critical locations on the RPV are subsequently identified based on the stress response. The stress intensity factors for the postulated flaws at those locations are then calculated, followed by an evaluation of the reactor's life in accordance with the ASME Boiler and Pressure Vessel Code Section XI. This comprehensive life assessment covers a number of transients expected during the flexible load-following operation, providing invaluable insights into the RPV's structural integrity. Moreover, the development methodology can be adapted to other reactor components, as well as components of conventional power stations that are affected by varying operating conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Magnesium Technology 2020

Magnesium and its alloys are being investigated widely for applications that require extraordinarily high strength-to-weight ratio, vibration damping, electromagnetic shielding, reduction in carbon footprint, sustainability improvements, and low toxicity. In the past decade or so, this drive has led to increased adoption of magnesium and its alloys in everyday products and it is no longer regarded as an esoteric material. The overarching goal of its widespread adoption and replacement of conventional materials such as steel and aluminum alloys has been restricted because of the cost of the material, limited sources of primary material, alloying constraints, high chemical reactivity, and challenges associated with its plasticity. Researchers, scientists, engineers, and economists from industry, government agencies and laboratories, and academic institutions alike are actively developing roadmaps for next-generation products and addressing these challenges as quickly as possible through unique and innovative methods. The TMS Magnesium Committee has been actively involved in providing a platform to these entities for disseminating the latest information, developments, and cutting-edge research and development, and showcasing the latest research and development trends related to magnesium and its alloys through the Magnesium Technology Symposium, which takes place every year at the TMS Annual Meeting. This proceedings volume retains the essence of this longstanding tradition. The twenty-first volume in the series, Magnesium Technology 2020, is the proceedings of the Magnesium Technology Symposium held during the 149th TMS Annual Meeting & Exhibition in San Diego, CA, February 23–27, 2020. The volume captures commentaries and papers from 15 different countries. The papers have been categorized systematically based on topics pertaining to magnesium production, casting and solidification, thermomechanical processing, deformation mechanisms, modeling, corrosion, and applications. The symposium began with keynote sessions that featured several distinguished invited speakers from government organizations and academia, who provided their perspectives on the state of the art, goals, and opportunities in magnesium alloy research and development. Dr. Carlos Tomé from Los Alamos National Laboratory, U.S. Department of Energy, discussed 3D characterization of mechanical twins across grain boundaries. This was followed by a talk on hierarchically structured ultrafine-grained magnesium alloys by Dr. Rajiv Mishra from the University of North Texas, USA, who presented an example of using friction stir additive manufacturing for implementing such microstructures at a component level. Dr. Mark Horstemeyer from Liberty University, USA, presented an overview of fatigue modeling to capture the corrosion-fatigue behavior of magnesium alloys. The final talk in this session was presented by Dr. Bin Jiang from Chongqing University, China, who presented a novel extrusion approach for achieving high-strength magnesium alloy plates.

Jordon, J. Brian↗