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At least 271 records · Page 15

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DOE OSTI2025

Molten Salt Corrosion Tests of Additively Manufactured Stainless Steel 316H

Molten salt reactors (MSRs) have drawn considerable interest due to their favorable safety features, high thermal efficiency, and compatibility with different fuel cycles. Yet, the success of MSRs hinges critically on the performance of structural materials to be used in these aggressive molten salt environments, where corrosion and material compatibility remain primary challenges to long-term reliability. Additively manufactured (AM) nuclear structural materials prompt the use of novel geometries and compositions to enhance material performance and reduce costs of constructing MSRs. The rapid solidification conditions inherent to AM processing impart distinctive microstructural features, including cellular sub-structures, dislocation densities, residual stress, and oxide inclusions, which can influence material performance in MSR components. While the mechanical properties of AM stainless steels have been widely studied, their corrosion behavior, particularly in molten salt environments, has received far less attention. Addressing these needs, the Advanced Materials and Manufacturing Technologies (AMMT) program provides a framework for systematically evaluating how unique microstructures produced by AM processes influence the performance of these materials in these demanding environments and for developing reproducible testing workflows that can support future code qualification efforts and standards development. Bridging this knowledge gap is essential for assessing the viability of AM alloys in MSRs and informing qualification strategies. A further challenge is the absence of standardized protocols for molten salt corrosion testing. Accordingly, this report provides an account of the corrosion evaluation of AM 316H stainless steel in NaCl 2 -MgCl 2 molten salt at 550 °C, with exposure times of 100 and 500 hours. It documents the experimental procedures implemented under the AMMT program, including salt preparation, exposure protocols, and post-test characterization methods, to establish reproducibility and transparency. Importantly, the study examines AM 316H samples in the as-fabricated condition, directly reflecting the surface state most relevant to engineering applications, and compares their behavior to machine-cut surfaces. Overall, preliminary evaluations have noted that surface conditions (e.g. morphology, contamination, etc.) have a noticeable impact on the corrosion resiliency. The impact of the corrosion is difficult to detect at 100h, unless, in the case of AM 316H, the specimen surface is decontaminated. After 500 h, as-fabricated surfaces of AM and wrought 316H display evidence of general versus preferential corrosion attack, respectively. Both AM and wrought 316H machine-cut surfaces exhibit a continuous Cr depletion zone, evident of general corrosion. While the estimated extent of corrosion appears within the same order of magnitude regardless of the surface condition, it is apparent that more predictable behavior is observed on machine-cut surfaces. Nonetheless, further investigation is necessary to fully elucidate the corrosion mechanism under these conditions.

36 - MATERIALS SCIENCE↗

NASA NTRS2002

Transient Reliability of Ceramic Structures For Heat Engine Applications

The objectives of this report was to develop a methodology to predict the time-dependent reliability (probability of failure) of brittle material components subjected to transient thermomechanical loading, taking into account the change in material response with time. This methodology for computing the transient reliability in ceramic components subjected to fluctuation thermomechanical loading was developed, assuming SCG (Slow Crack Growth) as the delayed mode of failure. It takes into account the effect of varying Weibull modulus and materials with time. It was also coded into a beta version of NASA's CARES/Life code, and an example demonstrating its viability was presented.

Nemeth, Noel N.↗

NASA NTRSDate not supplied

Effect of Synergistic Space Effects on Properties of Novel Polymer Composite Materials (PCM)

Evaluate the long-term performance of composite materials in space by exposing them to the actual space environment and analyzing changes in their interfacial properties, using the International Space Station (ISS) and the MISSE for experimentation. This research could assist in the design of future spacecraft, assessing risk and enhancing safety and reliability of spacecraft structural materials for space exploration.

R Vaidyanathan↗

NASA NTRS1984

Factors that affect the fatigue strength of power transmission shafting

A long standing objective in the design of power transmission shafting is to eliminate excess shaft material without compromising operational reliability. A shaft design method is presented which accounts for variable amplitude loading histories and their influence on limited life designs. The effects of combined bending and torsional loading are considered along with a number of application factors known to influence the fatigue strength of shafting materials. Among the factors examined are surface condition, size, stress concentration, residual stress and corrosion fatigue.

Loewenthal, S. H.↗

NASA NTRS1986

Factors that affect the fatigue strength of power transmission shafting and their impact on design

Leowenthal, S. H.↗

DOE OSTI2021

Challenges and transformative opportunities in superconductor vortex physics

In superconductors, the motion of vortices introduces unwanted dissipation that is disruptive to applications. Fortunately, material defects can immobilize vortices, acting as vortex pinning centers, which engenders dramatic improvements in superconductor material properties and device operation. This has motivated decades of research into developing methods of tailoring the disorder landscape in superconductors to increase the strength of vortex pinning. Yet, efficacious materials engineering still eludes us. The electromagnetic properties of real (disordered) superconducting materials cannot yet be reliably predicted, such that designing superconductors for applications remains a largely inefficient process of trial and error. This is ultimately due to large gaps in our knowledge of vortex dynamics: the field is challenged by the extremely complex interplay between vortex elasticity, vortex-vortex interactions, and material disorder. Here, we review obstacles and recent successes in understanding and controlling vortex dynamics in superconducting materials and devices. We further identify major open questions and discuss opportunities for transformative research in the field. This includes improving our understanding of vortex creep, determining and reaching the ceiling for the critical current, advanced microscopy to garner accurate structure-property relationships, frontiers in predictive simulations and the benefits of artificial intelligence, as well as controlling and exploiting vortices in quantum information applications.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2009

Recent Developments in Ultra High Temperature Ceramics at NASA Ames

NASA Ames is pursuing a variety of approaches to modify and control the microstructure of UHTCs with the goal of improving fracture toughness, oxidation resistance and controlling thermal conductivity. The overall goal is to produce materials that can perform reliably as sharp leading edges or nose tips in hypersonic reentry vehicles. Processing approaches include the use of preceramic polymers as the SiC source (as opposed to powder techniques), the addition of third phases to control grain growth and oxidation, and the use of processing techniques to produce high purity materials. Both hot pressing and field assisted sintering have been used to make UHTCs. Characterization of the mechanical and thermal properties of these materials is ongoing, as is arcjet testing to evaluate performance under simulated reentry conditions. The preceramic polymer approach has generated a microstructure in which elongated SiC grains grow in the form of an in-situ composite. This microstructure has the advantage of improving fracture toughness while potentially improving oxidation resistance by reducing the amount and interconnectivity of SiC in the material. Addition of third phases, such as Ir, results in a very fine-grained microstructure, even in hot-pressed samples. The results of processing and compositional changes on microstructure and properties are reported, along with selected arcjet results.

Johnson, Sylvia M.↗

NASA NTRS2012

Characterization and Analysis of Triaxially Braided Polymer Composites under Static and Impact Loads

In order to design impact resistant aerospace components made of triaxially-braided polymer matrix composite materials, a need exists to have reliable impact simulation methods and a detailed understanding of the material behavior. Traditional test methods and specimen designs have yielded unrealistic material property data due to material mechanisms such as edge damage. To overcome these deficiencies, various alternative testing geometries such as notched flat coupons have been examined to alleviate difficulties observed with standard test methods. The results from the coupon level tests have been used to characterize and validate a macro level finite element-based model which can be used to simulate the mechanical and impact response of the braided composites. In the analytical model, the triaxial braid unit cell is approximated by using four parallel laminated composites, each with a different fiber layup, which roughly simulates the braid architecture. In the analysis, each of these laminated composites is modeled as a shell element. Currently, each shell element is considered to be a smeared homogeneous material. Simplified micromechanics techniques and lamination theory are used to determine the equivalent stiffness properties of each shell element, and results from the coupon level tests on the braided composite are used to back out the strength properties of each shell element. Recent improvements to the model include the incorporation of strain rate effects into the model. Simulations of ballistic impact tests have been carried out to investigate and verify the analysis approach.

Goldberg, Robert K.↗

DOE OSTI2023

Formal Experimentation and Analysis of Handheld RFID Readers as a Tool for Nuclear Material Accounting

Commercial, off-the-shelf Radio Frequency Identification (RFID) systems have been successfully deployed for inventory tracking in numerous industries, but their viability in the tracking of complex environments containing nuclear material is less understood. Of primary interest in this setting is a RFID tracking system for nuclear material accounting which can reliably identify as many tags as possible with high accuracy, while also reducing an operator’s exposure to radiation. In this work, we develop a formal statistical approach to identify relevant handheld RFID reader settings which optimize tagging performance. To achieve this goal, we design a full factorial split-plot experiment for a static shelf configuration scene with 50 randomly placed nuclear material containers affixed with RFID tags. We use Bayesian inference to fit a second-order response surface model which expresses the probability of a successful match for each container as a function of the experimental factors. Such effects are allowed to vary across individual containers and the containers’ population in its entirety to estimate overall effects. Uncertainties of estimates and predictions are quantified via their corresponding posterior distributions. Following extensive model checking and validation, the fitted model is used to identify experimental factors which maximize matching probabilities at both the container-level and for the full shelf configuration scene. We also analyze sensitivity of performance to relevant factors.

25 ENERGY STORAGE↗

DOE OSTI2025

Uniform Mechanical Loading Can Test for Nonuniform Loading Durability

In this work, we present a method to evaluate the equivalency between any module mechanical loading conditions. The method is developed to address the specific failure mode of glass fracture and is based on Weibull analysis and weakest link theory. It considers the varying stress profile across the module to calculate the probability of glass fracture, which is used as the metric of equivalency. An idealized nonuniform loading scheme is employed to demonstrate the method and introduce the concept of the equivalent uniform load factor: a factor applied to the maximum pressure of the nonuniform load to obtain the equivalent uniform load value. It is demonstrated that this factor is less than unity for all nonuniform load cases considered, including snow and various characters of wind loading. These significant results suggest that uniform loading may be reliably, and practically, employed to evaluate photovoltaic module glass for nonuniform loading durability.

14 SOLAR ENERGY↗

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 OSTI2022

Physics-informed machine learning assisted uncertainty quantification for the corrosion of dissimilar material joints

Jointing techniques like the Self-Piercing Riveting (SPR), Resistance Spot Welding (RSW) and Rivet-Weld (RW) joints are used for mass production of dissimilar material joints due to their high performance, short cycle time, and adaptability. However, the service life and safety usage of these joints can be largely impacted by the galvanic corrosion due to the difference in equilibrium potentials between the metals with the presence of electrolyte. Here, in this paper, we focus on Al-Fe galvanic corrosion and develop physics-informed machine learning based surrogate model for statistical corrosion analysis, which enables the reliability analysis of dissimilar material joints under corrosion environment. In this study, a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode. Geometric and environmental factors including crevice gap, roughness of anode, conductivity, and the temperature of the electrolyte are investigated. Further, a thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al joints. It is found that the electrolyte conductivity has the largest effects on the material loss and needs to be managed closely for better corrosion control. This will help in designing and manufacturing joints with improved corrosion performance.

42 ENGINEERING↗

DOE OSTI2024

Uncertainty quantification in multivariable regression for material property prediction with Bayesian neural networks

With the increased use of data-driven approaches and machine learning-based methods in material science, the importance of reliable uncertainty quantification (UQ) of the predicted variables for informed decision-making cannot be overstated. UQ in material property prediction poses unique challenges, including multi-scale and multi-physics nature of materials, intricate interactions between numerous factors, limited availability of large curated datasets, etc. In this work, we introduce a physics-informed Bayesian Neural Networks (BNNs) approach for UQ, which integrates knowledge from governing laws in materials to guide the models toward physically consistent predictions. To evaluate the approach, we present case studies for predicting the creep rupture life of steel alloys. Experimental validation with three datasets of creep tests demonstrates that this method produces point predictions and uncertainty estimations that are competitive or exceed the performance of conventional UQ methods such as Gaussian Process Regression. Additionally, we evaluate the suitability of employing UQ in an active learning scenario and report competitive performance. The most promising framework for creep life prediction is BNNs based on Markov Chain Monte Carlo approximation of the posterior distribution of network parameters, as it provided more reliable results in comparison to BNNs based on variational inference approximation or related NNs with probabilistic outputs.

36 MATERIALS SCIENCE↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishment, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor (RSRM) represents the largest solid rocket motor (SRM) ever flown and the only human-rated solid motor. High reliability of the RSRM has been the result of challenges addressed and lessons learned. Advancements have resulted by applying attention to process control, testing, and postflight through timely and thorough communication in dealing with all issues. A structured and disciplined approach was taken to identify and disposition all concerns. Careful consideration and application of alternate opinions was embraced. Focus was placed on process control, ground test programs, and postflight assessment. Process control is mandatory for an SRM, because an acceptance test of the delivered product is not feasible. The RSRM maintained both full-scale and subscale test articles, which enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. RSRM reusability offered unique opportunities to learn about the hardware. NASA is moving forward with the Space Launch System that incorporates propulsion systems that takes advantage of the heritage Shuttle and Ares solid motor programs. These unique challenges, features of the RSRM, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, D. R.↗

DOE OSTI2025

Purification of legacy Ra-226 from ingrown Pb-210 using cation exchange chromatography

With the growing interest in using radium-226 (Ra-226) as a source material to produce essential radionuclides for targeted alpha therapies, the global demand for Ra-226 has surged, rendering its acquisition difficult. The shortage necessitates the exploration of alternative pathways to obtain this isotope beyond traditional commercial vendors. Legacy radium sources remain widespread due to Ra-226’s historical use but require the removal of ingrown daughter products to obtain a pure Ra-226 product. In conclusion, a straightforward and effective purification method for legacy Ra-226 ampoules has been developed using cation exchange chromatography, enabling the reliable conversion of legacy materials into high-purity Ra-226 solutions.

and nuclear chemistry↗

NASA NTRS1997

Enhanced CARES Software Enables Improved Ceramic Life Prediction

The NASA Lewis Research Center has developed award-winning software that enables American industry to establish the reliability and life of brittle material (e.g., ceramic, intermetallic, graphite) structures in a wide variety of 21st century applications. The CARES (Ceramics Analysis and Reliability Evaluation of Structures) series of software is successfully used by numerous engineers in industrial, academic, and government organizations as an essential element of the structural design and material selection processes. The latest version of this software, CARES/Life, provides a general- purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. CARES/Life was recently enhanced by adding new modules designed to improve functionality and user-friendliness. In addition, a beta version of the newly-developed CARES/Creep program (for determining the creep life of monolithic ceramic components) has just been released to selected organizations.

Janosik, Lesley A.↗

DOE OSTI2021

Multiscale Materials Characterization

The National Renewable Energy Laboratory (NREL) is advancing the state of the art in multiscale characterization to solve critical issues in materials science. We enthusiastically welcome industry, manufacturing, and government enterprises to partner with us on design integration that ranges from materials selection to manufacturing to reliability.

characterization↗

NASA NTRS2025

Erosion Results of the MISSE 9-15 Polymers and Composites Experiment 1-4 (PCE 1-4)

Polymers and other oxidizable materials on the exterior of spacecraft in the low Earth orbit (LEO) space environment can be eroded from reaction with atomic oxygen (AO). Therefore, in order to design durable spacecraft it is important to know the extent of erosion that will occur during a mission. This can be determined by knowing the LEO AO erosion yield, E y (volume loss per incident oxygen atom), of materials susceptible to AO reaction. In addition, recent flight experiments have shown that the AO E y can vary with the AO fluence and/or solar exposure. Therefore, obtaining AO E y data for materials flown on various spaceflight missions is important. NASA Glenn Research Center has flown numerous experiments as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS) to characterize the LEO E y of polymers, composites, protective coatings, and other spacecraft materials. Recently, four Glenn experiments with 365 flight (F) samples were flown on ISS’s MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. Although each experiment had numerous sample objectives, the primary objective was to determine the LEO AO E y of various spacecraft materials as a function of solar irradiation and AO fluence. This paper provides a summary of the erosion data for the PCE 1-4 AO E y samples. The AO E y for 150 samples flown in either the LEO ram, wake, zenith or nadir directions are provided. The AO ram fluence varied from 2.97×10 20 atoms/cm 2 after 0.89 years of direct space exposure (with relatively high levels of Si contamination) on MISSE 12 to 3.93×10 20 atoms/cm 2 after 1.17 years of direct space exposure on MISSE-10. The ram AO E y values for uncoated polymers range from 3.81×10 –25 cm 3 /atom for polytetrafluoroethylene (M9R-C20 F) exposed to an AO fluence of 3.44×10 20 atoms/cm 2 on MISSE-9 to 4.43×10 –23 cm 3 /atom for AO etched low density polyimide aerogel (M12R-C21 F) exposed to an AO fluence of 2.97×10 21 atoms/cm 2 on MISSE-12. Because of the low AO fluence and relatively high Si contamination, a number of PCE-3 wake samples experienced mass gain. Thus, AO E y values are not provided for these samples. Although there are calculated AO E y values for the zenith, wake and nadir samples, the ram AO E y for a particular material is a more reliable value in terms of AO exposure because the zenith, wake and nadir directions were exposed to either no or very little AO fluence and thus other space environmental factors (i.e. vacuum, thermal extremes and thermal cycling, and/or various types of radiation) are responsible for the mass loss.

Erosion yield↗