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At least 235 records · Page 13

Effect of Microstructural Bands on the Localized Corrosion of Laser Surface-melted 316L Stainless Steel

The localized corrosion of laser surface melted (LSM) 316L stainless steel is investigated by a combination of potentiodynamic anodic polarization in 0.1M HCl and microscopic investigation of the initiation and propagation of localized corrosion. The pitting potential of LSM 316L is significantly lower than the pitting potential of wrought 316L. The LSM microstructure is highly banded as a consequence of the high laser power density and high linear energy density. The bands are composed of zones of changing modes of solidification, cycling between very narrow regions of primary austenite solidification and very wide regions of primary ferrite solidification. Pits initiate in the outer edge of each band where the mode of solidification is primary austenite plane front solidification and primary austenite cellular solidification. The primary austenite regions have low chromium concentration (and possibly low molybdenum concentration), which explains their susceptibility to pitting corrosion. The ferrite is enriched in chromium, which explains the absence of pitting in the primary ferrite regions. The presence of the low chromium regions of primary austenite solidification explains the lower pitting resistance of LSM 316L relative to wrought 316L. The influence of banding on localized corrosion is applicable to other rapidly solidified processes such as additive manufacturing.

36 MATERIALS SCIENCE↗

Jet Fuel Production at the Pittsburgh Airport: GTL via Fischer-Tropsch Synthesis

The Pittsburgh International Airport (PIT)—with the Allegheny County Airport Authority (which manages PIT)—has established itself as a leader in resiliency by becoming the first major United States (U.S.) airport to have a self-sustaining microgrid, providing electricity, heating, and cooling for airport operations. The microgrid is powered by natural gas and solar power produced on the airport property and was completed in Summer 2021. This study examines the feasibility of producing jet fuel at the airport to provide a secure supply of aviation fuel, furthering PIT’s ability to weather supply disruptions and operate self-sufficiently. Gas-to-liquids (GTL) is a commercially available technology that converts natural gas to liquid hydrocarbons, including synthetic jet fuel. A GTL facility at PIT could convert natural gas from onsite wells to jet fuel, effectively doubling the onsite fuel stores in the event of a supply disruption. Moreover, GTL provides a pathway to renewable jet fuel production and reduced greenhouse gas (GHG) emissions from the aviation sector, particularly if renewable natural gas (RNG) is used as a feedstock or other renewable energy sources are used for energy inputs. This study has found that it would be technically feasible to construct and operate a GTL facility on PIT’s property. The approximately 6,000-barrel per day (BPD) facility evaluated would produce nearly 70 million (MM) gallons (gal) of synthetic jet fuel per year, which could supplant nearly all (85 percent) current jet fuel consumption at PIT. Given the current blend limitation of 50 percent Fischer-Tropsch fuels by volume, the plant would have excess production capacity available for the United States Air Force (USAF) Pittsburgh Air Reserve Station and the USAF 171st Air Refueling Wing co-located at the airport.

03 NATURAL GAS↗

ALDWP Operational Highlights 2021

The Weapons Pit production manufacturing team completed pit build 21-1 assembly operations on December 23, 2020. This build utilized all essential flow sheet steps and included the second -01 long tube cut off extension and welding activity. This is the best build produced in the MC4597-01 pit program to date. Final out-of-line operations, non-destructive evaluation, and radiography was completed during the week of January 4. Depending on the results from high energy radiography, this pit will be considered to be a candidate for CERT-02 and shipment to Lawrence Livermore National Laboratory in support of pit certification. It is notable that this build was completed while concurrently making Plutonium (Pu) metal, producing additional castings, machining Pu parts for Build 22, completing disassembly of two pits, supporting Nightshade B Pu target characterization, and precision machining of Jasper certification base plates.

42 ENGINEERING↗

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components. Third Annual Progress Report

Additive manufacturing (AM) of high-strength corrosion resistance alloys for nuclear energy applications, such as stainless steel and Inconel, is currently based on laser powder bed fusion (LPBF) process. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Probability of crack initiation at the pore depends on size, shape, and orientation of the defect. Pulsed Infrared Thermography Imaging (PIT) provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PIT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PIT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. Following initial qualification of an AM component for deployment in a nuclear reactor, a PIT system can also be used for in-service nondestructive evaluation (NDE) applications. In this report, we describe recent progress in enhancing PIT capabilities in detecting microscopic subsurface defects in metals, and classifying shapes and orientation of pores in thermal images. For detection of microscopic defects in PIT imaging data, we have developed Spatial Temporal Denoised Thermal Source Separation (STDTSS) unsupervised machine learning (ML) image processing algorithm. We show that flat bottom hole (FBH) defects as small as 200µm in SS316 and IN718 specimens, can be detected with STDTSS algorithm. To the best of our knowledge, these are the smallest detected defects which are reported in literature. For classification of defects shapes, we have previously developed thermal tomography (TT) algorithm to obtain depth reconstructions of material defects from data cube of sequentially recorded surface temperatures. However, interpretation of TT images is non-trivial because of blurring with increasing depth. To address this challenge, we have developed a deep learning convolutional neural network (CNN) to classify size and orientation subsurface defects in simulated TT images.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Corrosion study of bare and coated stainless steel

A program was conducted at Kennedy Space Center from February 1968 to February 1971 to evaluate the performance of austenitic stainless steel alloys used in fluid systems lines. For several years, there had been numerous failures of stainless steel hardware caused by pitting and stress corrosion cracking. Several alloys were evaluated for effectiveness of certain sacrificial-type protective coverings in preventing corrosion failures. Samples were tested in specially designed racks placed 91 meters (100 yards) above high-tide line at Cape Kennedy. It is concluded that: (1) unprotected tubing samples showed evidence of pitting initiation after 2 weeks; (2) although some alloys develop larger pits than others, it is probable that the actual pitting rate is independent of alloy type; (3) the deepest pitting occurred in the sheltered part of the samples; and (4) zinc-rich coatings and an aluminum-filled coating have afforded sacrificial protection against pitting for at least 28 months. It is believed that a much longer effective coating life can be expected.

Morrison, J. D.↗

Microcrater investigations on lunar rock 12002

Relative ages of 26 submillimeter-sized pits from an equilibrium population in rock 12002 were measured by determining the densities of pits 0.7 microns in diameter and larger on the submillimeter-sized pits. Production rates for 0.7 micron diameter pits were determined from solar-flare track exposure age measurements, and the data for rock 12002 are consistent with previously obtained data for sample 15205 if a lower meteoroid flux prevailed in the past. Metal mounds or spherules within a microcrater pit glass were found to have a meteoritic composition, and an impact lining consisting of protruding crystals was observed. The crystals apparently developed during exposure to space immediately after the 200-micron diameter pit was formed by impact into an olivine grain.

Hartung, J. B.↗

Weathering of basaltic rocks under cold, arid conditions - Antarctica and Mars

The processes taking part in the chemical weathering of nonvesicular dolerite cobbles producing etch pits and secondary minerals including clays, under cold arid conditions of high-altitude ice-free areas of Victoria Land (Antarctica) are investigated as a possible analog to processes that produced the pitted rocks and clay minerals on Mars. Results suggest that the pits in the dolerite cobbles are formed by the dissolution of the rock by rare snow-melt water during the austral summer, followed by wind erosion of weathered material. The upper interior walls of the pits are lined with a yellow precipitate consisting of illite and quartz mixture, while the pit bottoms contain alteration products including Fe-rich clay minerals and soluble salts. A model is proposed for rock pitting on Mars analogous to that of the Antarctic dolerites.

Allen, C. C.↗

Possible occurrence and origin of massive ice in Utopia Planitia

F. M. Costard recently discovered a large field of possible thermokarst depressions near latitude 45 deg N, longitude 270 deg, in western Utopia Planitia. Oval to circular pits are typically 300-1000 m across and approximately 25 m deep; larger depressions, 3-5 km across, are compound and seem to have formed by coalescence of smaller pits. Small domical hills occur on the floors of two pits. These depressions characteristically have steep, scalloped edges and one or more inner benches. Truncation relations of the benches suggest a discontinuous, lenslike stratification of the material in which the pits are developed. Based on a close analogy in form and scale with coalesced thawlake basins (alases) on Earth, the Martian pits may have formed by thermophysical interactions of pooled water with ice-rich permafrost. This interpretation is not unique; sublimation of ice-rich permafrost or possibly even eolian processes acting on ice-free material might have formed the pits. However, the regional setting contains many other indications of massive ice. Some of these features are examined.

Kargel, J. S.↗

Gear Damage Detection Using Oil Debris Analysis

The purpose of this paper was to verify, when using an oil debris sensor, that accumulated mass predicts gear pitting damage and to identify a method to set threshold limits for damaged gears. Oil debris data was collected from 8 experiments with no damage and 8 with pitting damage in the NASA Glenn Spur Gear Fatigue Rig. Oil debris feature analysis was performed on this data. Video images of damage progression were also collected from 6 of the experiments with pitting damage. During each test, data from an oil debris sensor was monitored and recorded for the occurrence of pitting damage. The data measured from the oil debris sensor during experiments with damage and with no damage was used to identify membership functions to build a simple fuzzy logic model. Using fuzzy logic techniques and the oil debris data, threshold limits were defined that discriminate between stages of pitting wear. Results indicate accumulated mass combined with fuzzy logic analysis techniques is a good predictor of pitting damage on spur gears.

Dempsey, Paula J.↗

Exploration of Planetary Skylights and Tunnels

While planetary pits and caves have been fiction for a century, they have been seen from orbit only in the last few years. These discoveries exceed the fantasies in diversity, scale, and abundance. For pits and caves, this is the age of discovery, ranging from a few pits on the Moon and Mars in 2009 to hundreds within the time of this research, with many more to come. Pits with subsurface voids have been confirmed on the Moon and Mars and indicated on Venus, Phobos, Eros, Gaspra, Ida, Enceladus, and Europa. Compelling next steps are surface and subsurface exploration.Pits and caves are opportunistic study targets for unique origins, geology, and climate that will broadly impact planetary science. Holes on Mars are of particular interest because their interior caves are relatively protected from the harsh surface, making them good candidates to contain Martian life. Pits are prime targets for possible future spacecraft, robots, and even human interplanetary explorers. Caves and caverns could be ready-_made shelters for future Moon and Mars explorers and colonists. Discoveries to date look down from on high with satellites but cannot reveal the wonders of caves. They cannot enter, touch, or view pits up close. Genuine exploration is only achievable through surface missions. Robotic missions can assess suitability for safe entry and habitation, plus inform techniques for developing subsurface infrastructure.Missions into planetary voids redefine the future of exploration, science, and habitation beyond Earth. We can reach this future only by targeting specific technological advancement now. Prior missions and current roadmap priorities target regions of benign terrain. While in-cave concepts have been postulated, the critical technologies have not been identified and demonstrated.While robotic exploration of skylights and caves can seek out life, investigate geology and origins, and open the subsurface of other worlds to humankind, it is a daunting venture. Planetary voids present perilous terrain requiring innovative technologies for access, exploration, and modeling. These same technologies are broadly applicable to explorations of rough and/or subsurface planetary environments, including caves, craters, cliffs, and rock fields. This research speculates on the possibilities and means of such exploration with fundamental contributions to exploring, modeling, and visualizing this new class of large-scale, highly three-dimensional concave planetary features.

Whittaker, Red↗

WRPS Hanford Update [Slides]

The purpose of this report is to coordinate with the staff from WRPS, the current contract holder for operations at the Hanford site to better inform design decisions for the Autonomous systems for Hanford waste tank handling project. The project goals are to support risk reduction associated with monitoring, inspection and mapping of Hanford tank underground pits and includes: 1. A pit mock-up demonstration of Idaho National Laboratory’s (INL) Autonomous Pit Exploration System (APES) technology, which has two configurations: A. The Autonomous Robotic Arm, which is a proposed collaboration with Florida International University (FIU) and has capabilities to visually inspect, monitor, map and conduct simple tool manipulation tasks in the tank pits, and B. The robotic crawler configuration, which has capabilities to deploy to the bottom of the pits and conduct closer and bottom-up visual inspections. 2. An Implementation Plan that identifies Hanford site-wide application of the INL remote robotics technologies to enhance the performance of the tank farm systems and the characterization of the waste they contain to mitigate risk and optimize the overall waste mission. 3. A first-of-a-kind environmental digital twin will be produced. Digital twins to date require permanently installed sensors in order to produce asset specific predictions. This project will use the intermittent signals during inspections from deployed sensors on robotic systems to produce the data sets used by AI/ML to enable predictions of issues on tanks.

42 - ENGINEERING↗

Improving Abundance Estimates of Spring–Summer Snake River Chinook Salmon for Fisheries Management

Abstract The Columbia River basin is home to a run of spring–summer Chinook Salmon Oncorhynchus tshawytscha that returns to the Snake River drainage of Idaho, Oregon, and Washington in the Pacific Northwest. Historically, the run was one of the more productive throughout the Columbia River basin. However, Snake River spring–summer Chinook Salmon have experienced declines in abundance due to overfishing, habitat degradation, and dams. Several stocks are listed as threatened under the U.S. Endangered Species Act and are supported by mitigation hatcheries funded by Idaho Power Company, the Lower Snake River Compensation Plan, and the Bonneville Power Administration. To maximize tribal and state harvest of returning hatchery adults, minimize impacts on wild fish, and ensure that enough hatchery fish return to meet broodstock needs, careful fisheries management is required. Since 2008, managers have used hatchery adults, PIT-tagged as juveniles and detected at Lower Granite Dam, to generate adult abundance estimates. In season, these estimates inform state and tribal harvest shares and ensure that broodstock needs are met. Postseason, they provide smolt-to-adult survival and return rates. Since 2012, parentage-based tagging (PBT) has provided an alternative method to estimate stock- and age-specific returns at Lower Granite Dam, since returning hatchery adults sampled at Lower Granite Dam can be assigned to their parents. We compared stock-specific abundance estimates between PIT- and PBT-derived methodologies for return years 2016–2019. Across all years, PIT tag estimates accounted for 65% of the PBT-based estimates at Lower Granite Dam across all age-groups and release sites combined. This underrepresentation across all groups equated to 49,833 fish that were not accounted for in PIT tag abundance estimates. It is clear that PBT-based estimates should aide in-season harvest management and postseason run reconstruction to avoid the known bias of estimates from PIT tags, especially during years of low returns when increased accuracy is critical.

Coykendall, D. Katharine (ORCID:0000000211482397)↗

A subdermal tagging technique for juvenile sturgeon using a new self-powered acoustic tag

Abstract Background A new technology for a self-powered acoustic tag (SPT) was developed for active tracking of juvenile fish, intended to avoid the typical battery life constraints associated with active telemetry technology. We performed a laboratory study to evaluate a subdermal tagging technique for the SPT and effects of the tag on survival, tag retention, and growth in juvenile white sturgeon ( Acipenser transmontanus ). Results Survival was associated with tag retention. White sturgeon implanted with the SPT ( n = 30) had 93% survival and tag retention by day 28, 67% by day 101, and 38% by day 595 post-tagging. Sturgeon implanted with a passive integrated transponder (PIT) tag only (control group) had 96% survival and tag retention by day 28, and through day 101 post-tagging. Fish in the PIT group were repurposed after day 101, so no comparisons with this group were made at day 595 post-tagging. Specific growth rate (SGR) for fork length was a median of 0.25% day −1 by day 28 for the SPT group, which was significantly lower than the PIT group (median: 0.42% day −1 ; n = 27). The SPT and PIT groups had similar SGR fork length by day 101 post-tagging (0.22 and 0.25% day −1 , respectively). SGR weight was also lower for the SPT group compared to the PIT group on day 28 (1.39 and 2.11% day −1 , respectively), but the difference again dissipated by day 101 (0.79 and 0.88% day −1 , respectively). Conclusion The tagging technique and placement of the SPT allowed the tag to remain upright along the flank of the sturgeon to ensure maximum battery output of the SPT; however, retention rates of the SPT were not ideal. We provided suggestions to improve the tagging technique. Suggestions included tagging fish that are > 400 mm FL, moving the incision location to extend the cavity and create a pocket for the placement of the SPT, and performing a quantitative wound-healing evaluation. Future studies are therefore recommended to evaluate these suggestions.

59 BASIC BIOLOGICAL SCIENCES↗

Hanford Double Shell Waste Tank Corrosion Studies (Final Report FY2019)

During fiscal year (FY) 2019, the Savannah River National Laboratory (SRNL) focused on four primary tasks for Hanford Double Shell Tanks (DSTs) corrosion studies. The first task, New Limits, was a continuation from the electrochemical work started in FY16, to expand electrochemical testing to elevated temperatures and elevated hydroxide concentrations and evaluate how these factors will influence pitting corrosion. Using the pitting factor (PF) equation, these new conditions were validated to provide a conservative estimate for the susceptibility of pitting corrosion on legacy carbon steel. The second task, Secondary Liner Corrosion, focused on Vapor Space Corrosion (VSC) and immersion testing studies using two commercially available vapor corrosion inhibitors (VCIs). For this FY, the VCI strategy was applied mid-experiment to determine performance on weathered coupons. The third task, Long-Term Open Circuit Potential (OCP) Drift, was performed using simplified simulated chemistries to evaluate change in pitting corrosion risk due to evolution of corrosion potential for mill-scale and freshly polished 600-grit surfaces. Finally, the fourth task, Microbiologically-Influenced Corrosion (MIC) studies, was focused on the study of leak detection pit (LDP) water sent from the Hanford tank farm for determination of bacteria that can be conducive to corrosion using commercially available kits: BART TM and MICkit® 5. In addition, this FY, a secondary task was added which was a continuation of the study of the Quartz-enhanced Photoacoustic Spectroscopy (QEPAS) system. Work was started but was ultimately not pursued. A summary of each task performed is presented below.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Pulsed Infrared Thermography Nondestructive Imaging of SiC-SiC f Composite Cladding Architectures; Understanding the Performance of SiC-SiC f Composite Cladding Architectures with Cr Coating in Normal Operating and Accident Conditions in LWRs and Advanced Reactors

SiC-SiC f composites, consisting of silicon carbide fibers embedded in a silicon carbide matrix, are advanced materials with high thermal conductivity, temperature stability, and resistance to radiation damage. Traditional methods for quality control of fabricated SiC-SiC f composites involve nondestructive evaluation (NDE) with X-ray computed tomography (XCT). However, XCT imaging of typical SiC-SiC f structures for cladding applications can involve several hours. In this project, we investigate an alternative approach to NDE of SiC-SiC f composites that involves rapid (on the order of seconds) imaging with Pulsed infrared thermography (PIT). PIT images of a planar SiC-SiC f specimen show the structure of the surface monolith layer and internal SiC f structures. The capability of PIT imaging in visualizing SiC f structures is qualitatively confirmed by observing similarity in the PIT and X-ray transmission images of the same specimen. Computer vision analysis of defects in the PIT image of the monolith was performed with thresholding followed by topological structural analysis that computed geometric descriptors, including major/minor axes of fitted ellipses, area, perimeter, Feret diameter, circularity, roundness, and solidity.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

New lunar microcrater evidence against a time varying meteoroid flux

An attempt to measure the relative times of formation of 25 microcraters on lunar rock 60015 is discussed which was carried out as part of a study of the flux of interplanetary dust and possible time variations of that flux over periods of 1000 to 1 million yr. The data obtained could indicate that the formation rate of 100-micron-sized pits was lower in the past as compared with the formation rate of micron-sized pits, that the flux of particles forming 100-micron-sized pits may have varied relative to that of particles forming micron-sized pits, or that 100-micron-sized pits are forming now at a higher rate, relative to the formation rate of accretionary disks, than in the past. The last suggestion is shown to be almost untenable, and the overall results are found to lead to a logical paradox. It is concluded that the attempt probably failed and that the reason for failure raises serious questions regarding the use of lunar rock surfaces as meteoroid detectors.

Hartung, J. B.↗

Impingement-Current-Erosion Characteristics of Accelerator Grids on Two-Grid Ion Thrusters

Accelerator grid sputter erosion resulting from charge-exchange-ion impingement is considered to be a primary cause of failure for electrostatic ion thrusters. An experimental method was developed and implemented to measure erosion characteristics of ion-thruster accel-grids for two-grid systems as a function of beam current, accel-grid potential, and facility background pressure. Intricate accelerator grid erosion patterns, that are typically produced in a short time (a few hours), are shown. Accelerator grid volumetric and depth-erosion rates are calculated from these erosion patterns and reported for each of the parameters investigated. A simple theoretical volumetric erosion model yields results that are compared to experimental findings. Results from the model and experiments agree to within 10%, thereby verifying the testing technique. In general, the local distribution of erosion is concentrated in pits between three adjacent holes and trenches that join pits. The shapes of the pits and trenches are shown to be dependent upon operating conditions. Increases in beam current and the accel-grid voltage magnitude lead to deeper pits and trenches. Competing effects cause complex changes in depth-erosion rates as background pressure is increased. Shape factors that describe pits and trenches (i.e. ratio of the average erosion width to the maximum possible width) are also affected in relatively complex ways by changes in beam current, ac tel-grid voltage magnitude, and background pressure. In all cases, however, gross volumetric erosion rates agree with theoretical predictions.

Barker, Timothy↗