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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 289 records · Page 16

Exploring the speciation of actinide salts in the presence of contaminants related to molten salt reactors

Molten salt reactors (MSR) are up-and-coming Generation IV nuclear reactors with either coolant and/or radioactive fuel in molten salt form. Due to their improved safety, efficiency, affordability and convenient waste processing system, these reactors are considered a superior alternative to conventional ones. However, prior to commercial implementation, it is necessary to have an extensive understanding of the reactions occurring in the MSR. The safety parameters of the MSR are determined by the rheological properties such as density and viscosity of the molten salt and these properties are governed by the local structure of the molten salts. Due to the high operational temperatures of MSR's, corrosion plays an important role. Because of their influence, the container corrosion products become part of the fuel salt matrix. In this work, we are investigating how these corrosion products, e.g., Mo, Ni, Cr, would impact the speciation of the actinide metal centers. For the initial studies, lanthanides are used as a surrogate for actinides. Lanthanide chloride salts (LnCl3) are mixed with transition metals and excess of alkali or alkali earth metal salts or salt mixtures (LiCl, NaCl, KCl). These are added to an alumina crucible, placed in a quartz tube, and sealed under a vacuum. This is heated up to around 1000 °C and slowly cooled to a temperature above the melting point of the salt and at that temperature, the reaction is taken out of the furnace. The excess salt is removed, and the resulting product is analyzed using X-ray diffraction techniques, scanning electron microscopy, and spectroscopic methods such as Raman, UV-Visible, and FTIR spectroscopy.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗

Dynamic Modeling of Latent Heat Thermal Battery

A dynamic thermodynamic model is constructed in Modelica for the thermal battery portion of a heat pipe integrated thermal battery and is demonstrated using a shakedown test. The model is also leveraged to inform aspects of an experiment configuration. The theory section discusses modeling assumptions of the thermal battery system, establishes how melting and fusing is calculated, and how internal convection is modeled within the thermal battery. The shakedown test uses three charge-standby-discharge-standby cycles in which the charging cycles are 10 hours in length and the discharge cycles are 8 hours. System behavior including heat loss, temperature distributions and divergences, and internal convection behavior are presented. The model is then leveraged to show how experiment design can be informed through testing the model for insulation thickness impact on heat loss, round trip efficiency calculation, and heat tracing control.

25 ENERGY STORAGE↗

Large-Scale Compatibilization of Postconsumer Polyolefins in the Presence of Paraffin Wax as a Rheology Modifier

Postconsumer polyolefins (r-POs) are leading plastic waste contributors today. This study reports, for the first time, the compatibilization of r-POs at a 50 kilogram (kg) scale with a styrene block copolymer compatibilizer in the presence of paraffin waxes as rheology modifiers (RMs). The addition of the rheological modifier (RM) and compatibilizer enhances the melt flow indices (MFIs) and mechanical properties, respectively. One aspect of this study is to compare the effectiveness of low-cost paraffin wax to that of specialized and expensive RMs in r-POs. The mechanical and rheological properties such as the melt flow index (MFI) of r-POs were compared in the presence of two types of RMs. Next, the study explores the challenges encountered when scaling the compatibilization of r-POs in the presence of paraffin wax from a 10-g to a 50-kg scale. The mechanical properties were determined and compared for samples at different scales. The study further investigated the effect of the method used for blending paraffin wax with r-PO and its impact on the value of their MFI and mechanical properties. This at-scale validation could pave the way for the commercialization of r-POs.

crystallinity↗

Exploring the Impact of Copper Oxide Substitution on Structure, Morphology, Bioactivity, and Electrical Properties of 45S5 Bioglass®

In recent decades, the requirements for implantable medical devices have increased, but the risks of implant rejection still exist. These issues are primarily associated with poor osseointegration, leading to biofilm formation on the implant surface. This study focuses on addressing these issues by developing a biomaterial for implant coatings. 45S5 bioglass® has been widely used in tissue engineering due to its ability to form a hydroxyapatite layer, ensuring a strong bond between the hard tissue and the bioglass. In this context, 45S5 bioglasses®, modified by the incorporation of different amounts of copper oxide, from 0 to 8 mol%, were synthesized by the melt–quenching technique. The incorporation of Cu ions did not show a significant change in the glass structure. Since the bioglass exhibited the capacity for being polarized, thereby promoting the osseointegration effectiveness, the electrical properties of the prepared samples were studied using the impedance spectroscopy method, in the frequency range of 102–106 Hz and temperature range of 200–400 K. The effects of CuO on charge transport mobility were investigated. Additionally, the bioactivity of the modified bioglasses was evaluated through immersion tests in simulated body fluid. The results revealed the initiation of a Ca–P-rich layer formation on the surface within 24 h, indicating the potential of the bioglasses to enhance the bone regeneration process.

Hammami, Imen (ORCID:0000000290072221)↗

LANSCE Module 1 Capacitor Room Failure [Slides]

At ~3:30 am on Sunday, high-voltage line in capacitor room overheated to the extent that the poly insulating material caught fire and dripped melted insulation onto equipment below. LAFD responded and, per pre-incident planning, waited for AOT personnel to respond to the area. AOT personnel, safed equipment and waited with LAFD for fire to “burn out”. Using an IWD, AOT personnel safely re-entered the area after conducting hazards analysis and engaging SMEs, re: controls for combustion products and COVID-19 hazards. Recovery action took several days with a focus on getting it right. Beam re-start decisions were made with impacted organizations and considering AOTRFE personnel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Polymorphs of the n–Type Polymer P(NDI2OD–T2): A Comprehensive Description of the Impact of Processing on Crystalline Morphology and Charge Transport

A systematic study of the polymorphs emerging in P(NDI2OD-T2) (also commercially known as N2200), a prototypical organic semiconducting n-type polymer, is presented. Using a tightly integrated experimental and computational approach, detailed atomistic-level descriptions are provided investigating the three known P(NDI2OD-T2) polymorphs observed at room temperature as a function of thin-film processing. Importantly, over the course of the work, a missing link is uncovered, a fourth polymorph referred to here as Form I-β; this new form is a morphological intermediary observed upon thermal annealing, which evolves from Form I but tends to disappear upon full polymer chain melting. The computationally derived polymorph structures show excellent agreement with experimental X-ray scattering characterization. The relative stabilities of each polymorph are calculated in terms of both the bulk material and the polymorph-air interface. An energy landscape is then constructed to qualitatively compare the thermodynamic versus kinetic origins of each polymorph, and the factors driving (supra)assembly and associated transformations among polymorphs using an approach generalizable to other organic semiconducting polymers. Lastly, the relationships among preferential polymorphic crystallinity, relative chain orientations, and directional charge transport properties in P(NDI2OD-T2) are explored. Altogether, this work provides unprecedented insights into complex structure-processing-transport relationships in a representative semiconducting organic polymer.

36 MATERIALS SCIENCE↗

Effect of coaxial nozzle wear on catchment efficiency in direct energy deposition built components

Laser based Direct Energy Deposition (DED) systems using metallic powder feedstock are recognized as a promising manufacturing method for their ability to shorten production cycles and create complex part geometries. Components are built by generating a melt pool with a high-power laser beam while material is coaxially injected and left to solidify. An impediment to large scale use of DED lies in poor powder catchment efficiency, the condition in which a portion of injected powder escapes the melt pool resulting in a ratio of decreased printed material mass to mass of supplied feedstock. The wear state of a coaxial nozzle on a DED system within a hybrid manufacturing machine tool has been observed to decrease catchment efficiency over time. Herein this study investigates this effect by adapting flow visualization techniques to an in-situ process monitoring format, the implementation of a Computational Fluid Dynamics (CFD) simulation, and deposition testing. Nozzle geometric defects due to wear are identified and categorized, and the impact of nozzle tip wear, resulting in axial tip reduction, on powder catchment efficiency is proven by multiple calculation methods. A linear correlation between catchment efficiency and powder stream diameter is identified, causing a 15–20% loss in efficiency sustained over incremental nozzle tip reduction up to − 1 mm. These results provide a foundation for further study of wear effects and Zero defect manufacturing solutions for powder fed DED systems.

42 ENGINEERING↗

Low-temperature selective laser sintering 3D printing of PEEK-Nylon blends: Impact of thermal post-processing on mechanical properties and thermal stability

Herein, a high-performance polymer (HPP) (polyether ether ketone, PEEK) blended with a commercial low-temperature polymer (polyamide 12, PA-12) was fabricated using a low-temperature selective laser sintering (SLS) 3D printer. Different post-processing heat treatments were implemented after fabrication to tune the thermal and mechanical properties of printed blends. The specific mechanical modulus of the blend was increased up to 79% in comparison to printed PA-12 samples with heat treatment. Additionally, the thermal resistance of the treated blends greatly exceeded the properties observed using PA-12 alone. This research proposes a methodology to fabricate and engineer HPP using desktop SLS printers through a secondary lower melting temperature material and heat treatments.

36 MATERIALS SCIENCE↗

Morpho-physiological and transcriptomic responses of field pennycress to waterlogging

Field pennycress (Thlaspi arvense) is a new biofuel winter annual crop with extreme cold hardiness and a short life cycle, enabling off-season integration into corn and soybean rotations across the U.S. Midwest. Pennycress fields are susceptible to winter snow melt and spring rainfall, leading to waterlogged soils. The objective of this research was to determine the extent to which waterlogging during the reproductive stage affected gene expression, morphology, physiology, recovery, and yield between two pennycress lines (SP32-10 and MN106). In a controlled environment, total pod number, shoot/root dry weight, and total seed count/weight were significantly reduced in SP32-10 in response to waterlogging, whereas primary branch number, shoot dry weight, and single seed weight were significantly reduced in MN106. This indicated waterlogging had a greater negative impact on seed yield in SP32-10 than MN106. We compared the transcriptomic response of SP32-10 and MN106 to determine the gene expression patterns underlying these different responses to seven days of waterlogging. The number of differentially expressed genes (DEGs) between waterlogged and control roots were doubled in MN106 (3,424) compared to SP32-10 (1,767). Functional enrichment analysis of upregulated DEGs revealed Gene Ontology (GO) terms associated with hypoxia and decreased oxygen, with genes in these categories encoding proteins involved in alcoholic fermentation and glycolysis. Additionally, downregulated DEGs revealed GO terms associated with cell wall biogenesis and suberin biosynthesis, indicating suppressed growth and energy conservation. Interestingly, MN106 waterlogged roots exhibited significant stronger regulation of these genes than SP32-10, displaying a more robust transcriptomic response overall. Together, these results reveal the reconfiguration of cellular and metabolic processes in response to the severe energy crisis invoked by waterlogging in pennycress.

ERF-VII↗

Melt extruded versus extrusion compression molded glass-polypropylene long fiber thermoplastic composites

Long fiber thermoplastic (LFT) composites are processed either with extrusion compression or fiber injection processes. The properties of LFT materials are highly influenced by processing techniques, which lead to different porosity contents, fiber length distributions, and fiber orientation distributions. It is important to understand the various LFT processing techniques and their effects on mechanical, thermal, and microscopic properties. This work considered LFT sheets processed via extrusion, which offers highly aligned fibers (referred to as “Tecnogor composites”), and LFT composites produced via extrusion compression molding (ECM), which offers a random distribution of fibers. Tecnogor composites exhibited higher flexural strength (35–65%), flexural modulus (132–172%), tensile strength (39–52%), tensile modulus (67–75%), and Izod impact resistance (195–220%) than the random LFT composites. This response was attributed to the aligned fibers in Tecnogor composites. Mathematical models including Halpin-Tsai and Lavengood-Goettler were used to predict and compare the Young’s modulus of Tecnogor and ECM composites, respectively.

mechanical testing↗

Fluoropolymer Aging Phenomena

This project aims to investigate structural and morphological changes in fluoropolymers induced by both processing and aging phenomena such as heat, time, and irradiation. Fluoropolymers are an important class of thermoplastics that are broadly used in industry as o-rings and seals when chemical resistance and thermal performance are important. They are also often used in thin film geometries as binders in batteries, insulation layers, water barriers, and anti-fouling coatings. For all of these applications, mechanical integrity and aging are important aspects of their use. Changes in the crystalline morphology are known to impact the mechanical properties of the polymer and can lead to failure. The broad goals of this project are to correlate compositional changes, morphological changes, and mechanical changes. report focuses on the morphological changes that are correlated with nuclear magnetic resonance (NMR), calorimetry and mechanical testing. We plan to compare structure and morphology measurements across complementary bulk and surface techniques. We use in situ atomic force microscopy (AFM) to measure domain shape and crystallization kinetics; in situ NMR to measure crystalline composition; and differential scanning calorimetry (DSC) to measure melting temperatures.

36 MATERIALS SCIENCE↗

Cloud-atmosphere impacts on the central Arctic surface energy budget (Final Report)

This project investigated how clouds and atmosphere-sea ice interactions shape the central Arctic surface energy budget using observations from the MOSAiC expedition and coordinated model experiments. Analyses focused on three themes. First, a new method applied to thermistor string data revealed that snow thermal conductivity is systematically higher than assumed in most models, strongly influencing conductive heat flux and sea ice growth, especially under clear skies. Second, a full annual cycle of surface energy budget observations, combined with detailed cloud microphysical retrievals, demonstrated how cloud regimes regulate radiative, turbulent, and conductive fluxes, driving seasonal contrasts in sea ice energy balance: in winter, radiative forcing elicits strong turbulent and conductive responses, while in summer excess energy is primarily partitioned into surface melt. Third, these observations were used to evaluate and improve regional and global forecast models. While some models captured key Arctic cloud-radiation states, most exhibited persistent deficiencies in representing liquid-containing clouds, snow-on-sea-ice processes, and flux responses to radiative forcing. Together, these results provide unprecedented benchmarks for understanding coupled Arctic processes, improve parameterizations of snow, sea ice, and cloud interactions, and highlight critical pathways by which atmospheric variability drives sea ice change in a rapidly evolving Arctic system. Lastly, the project was a resounding success, resulting in 38 peer-reviewed publications and dozens of presentations, while also supporting an early career scientist.

54 ENVIRONMENTAL SCIENCES↗

Melt compounding of spray-dried cellulose nanofibrils/polypropylene and their application in 3D printing

Abstract Micro- and nano-scale cellulosic fillers exhibit excellent dispersion and distribution within a thermoplastic matrix during the process of melt compounding or injection molding. In this study, spray-dried cellulose nanofiber (SDCNF) powders were manufactured using a pilot-scale rotating disk atomizer spray dryer. Bleached Kraft pulp (BKP), unbleached Kraft pulp (UKP), and old corrugated cardboard pulp (OCC) fibrillated at a fines level of 90% were used as feedstock materials for spray-drying. BKP-, UKP-, and OCC- SDCNFs were compounded with polypropylene using a twin screw co-rotating extruder. Maleic anhydride grafted polypropylene (MAPP) was used as a coupling agent in the composite formulations. The tensile, flexural, and impact properties of SDCNF-filled PP composites increased at 10 wt% SDCNF loading. The presence of SDCNFs in the PP matrix resulted in faster crystallization and a 12% reduction in the degree of crystallinity of the neat PP. The coefficient of thermal expansion (CTE) of neat PP was reduced by up to 31% attributable to the presence of the SDCNFs. Application of the SDCNF-reinforced PP composites in 3D printing reduced the shrinkage rate of the printed neat PP by 39%, and the printability of the PP was significantly improved with the addition of the SDCNFs.

Materials Science↗

Quantitative Morphological Characterization of Carbide Inclusions in Uranium Metal

Uranium carbides (UCs) are prevalent inclusions in U metal that form during melting operations from interactions with crucible walls and the casting chamber atmosphere. Although UCs have been studied extensively since the beginning of U metal foundry operations, there are still unknowns regarding the effects of thermomechanical processing on their sizes and morphology. Here, we present the results of a series of controlled cooling experiments with molten uranium to elucidate the effect of cooling rate on inclusion morphology in a-U. Samples were melted using a vacuum induction melter and manually cooled at rates of 2.5, 1.7, 1.1, 0.8, 0.3 (± 1%) K/s from ~1600 K to <700 K in under 1 hour. Subsequent scanning electron microscopy (SEM) was performed on cross-sections of the samples, revealing a complex mixture of UC morphologies that are indicative of diffusion and growth influenced by the thermal processing of the U matrix. Image analysis using the Morphological Analysis of Materials (MAMA) software showed that UC sizes generally grew larger with slower cooling rates, and the two slowest cooling rates noticeably impacted the inclusion circularity and ellipse aspect ratio. These results indicate that UC morphology is sensitive to short cooling rates (<1 hour) and could therefore be controlled in the production of metallic nuclear fuels. Additionally, inclusion speciation and morphologies could potentially provide forensic clues about processing history of unknown metal samples. Understanding the driving forces involved in UC morphology evolution is beneficial for evaluating metal fuels for next generation nuclear reactors and for identifying signatures for nuclear forensics.

Athon, Matthew T.↗

Unified understanding of the impact of semiflexibility, concentration, and molecular weight on macromolecular-scale ring diffusion

Conformationally fluctuating, globally compact macromolecules such as polymeric rings, single-chain nanoparticles, microgels, and many-arm stars display complex dynamic behaviors due to their rich topological structure and intermolecular organization. Synthetic rings are hybrid objects with conformations that display both ideal random walk and compact globular features, which can serve as models of genomic DNA. To date, emphasis has been placed on the effect of ring molecular weight on their unusual behaviors. Here, we combine simulations and a microscopic force-level theory to build a unified understanding for how key aspects of ring dynamics depend on different tunable molecular properties including backbone rigidity, monomer concentration, degree of traditional entanglement, and molecular weight. Our large-scale molecular dynamics simulations of ring melts with very different backbone stiffnesses reveal unanticipated behaviors which agree well with our generalized theory. This includes a universal master curve for center-of-mass diffusion constants as a function of molecular weight scaled by a chemistry and thermodynamic state-dependent critical molecular weight that generalizes the concept of an entanglement cross-over for linear chains. The key physics is how backbone rigidity and monomer concentration induced changes of the entanglement length, interring packing, degree of interpenetration, and liquid compressibility slow down space-time dynamic-force correlations on macromolecular scales. A power law decay of the center-of-mass diffusion constant with inverse molecular weight squared is the first consequence, followed by an ultraslow activated hopping transport regime. Our results set the stage to address slow dynamics and kinetic arrest in different families of compact synthetic and biological polymeric systems.

Science & Technology - Other Topics↗

Progress Towards a Titanium-Zirconium-Molybdenum Alloy Coreblock Prototype Using Powder Bed Fusion

Microreactor designs make use of a coreblock for structural stability allowing for these devices to provide powder generation while being portable and inherently safe. In order to maximize energy output of the microreactors, materials must be able to withstand high temperature without melting and without substantial decreases in mechanical properties. As simultaneous projects looking at steels, graphite, and other materials are on-going, this work package will investigate titanium – zirconium – molybdenum alloy (TZM) as it allows for potentially higher microreactor operating temperatures than traditional reactor materials such as stainless steel. Notably, this alloy was developed in the 1960s for use in rockets and has a very high melting point (2623°C) but is difficult to form, machine and join. With limited needs in aerospace, literature is appropriately sparce in looking at the AM of TZM (examples include [1,2]). However, the properties appear to be an excellent match for the needs of the microreactor coreblock leading to the current project. In addition, small washers form the bulk of TZM parts needed in aerospace while the microreactor community was looking at larger, more complex parts. Therefore, AM of TZM is being explored to enable near – net shape of components with the needed complexity to impact the nuclear energy field.

36 MATERIALS SCIENCE↗

The Effects of Mixing Multi-Component HLW Glasses on Spinel Crystal Size

The Hanford Waste Treatment and Immobilization Plant will vitrify radioactive waste into borosilicate glass. The high-level waste (HLW) glass formulations are constrained by processing and property requirements, including restrictions aimed at avoiding detrimental impacts of spinel crystallization in the melter. To understand the impact of glass chemistry on crystallization, two HLW glasses precipitating small (?5 µm) spinel crystals were individually mixed with a glass that precipitated large (?45 µm) spinel crystals in ratios of 25, 50, and 75 wt%. The size of spinel crystals in the mixed glasses varied from 5 to 20 µm. Small crystal size was attributed to: (1) high concentrations of nuclei due to the presence of ruthenium oxide and (2) chromium oxide aiding high rates of nucleation. Results indicate that the spinel crystal size can be controlled using chromium oxide and/or noble metal concentrations in the melt, even in complex mixtures like HLW glasses. Small crystals tend to settle slowly, so they are acceptable in the melter without a risk of failure. Allowing higher concentrations of spinel-forming waste components in the waste glass enables glass compositions with higher waste loading, thus increasing plant operational flexibility. An additional benefit to the presence of chromium oxide in the glass composition is the potential for the oxide to protect melter walls against corrosion.

Lonergan, Charmayne E.↗