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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Mechanical response and microstructure evolution from multiaxial stress relaxation in textured zircaloy nuclear cladding

Modern energy markets provide motivation for nuclear reactors to increase operational flexibility and load following capacity of existing reactor designs. The operational power changes result in fuel pellet expansion and contraction resulting in pellet-cladding mechanical interaction (PCMI) and high cladding stresses that are strongly related to stressed corrosion cracking (SCC) which can lead to fuel rod failure. This work aims to quantify the stress fields in cladding with a focus on multiaxial stress relaxation response from an imposed strain and the resulting microstructure changes in textured zircaloy claddings. Stress relaxation tests resulting in multiaxial stress fields are performed to measure the material response of Zircaloy-4 nuclear cladding. Multiple experiments using samples from the same piece of cladding are performed so samples with the same processing history may be removed at strategic points throughout mechanical testing for microstructure characterization. The microstructure evolution is analyzed with mechanical response to evaluate the static recovery impact on crystallographic texture and grain morphology. Experiments are performed at Idaho National Laboratory using an experimental device capable of applying internal pressure and independent axial load to commercial nuclear cladding at elevated temperatures with stress- or strain-controlled experimental capability. X-ray diffraction and electron backscatter diffraction are used for microstructure analysis. Rheological models are used to visualize the multiaxial stress-strain relationships and isolate elastic, plastic, and viscoplastic material properties for analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Helium Release During Fracture and Granular Fragmentation of Rocks

Geogenic Helium-4 ( 4 He) in-situ increases locally in regions of large deformation generated naturally or anthropogenically. This gas release by deformation is a potential geochemical precursor signal for subsurface deformation. To evaluate the applicability of 4 He degassing for correlating deformation in different lithologies, we conducted high force crush tests, up to 97,800 N axial load, to assess the total 4 He released during fragmentation of the rocks. We observed that the highest 4 He released occurred in the sedimentary rocks and that release correlated strongly with lithologic age and U/Th content. Microstructural changes of the pre- and post-test rocks indicate that the degree of grain size reduction relates directly to the total 4 He released during crushing. The range of in-place 4 He was calculated based XRF measurements of uranium and thorium in each lithology, with the results indicating that the majority of the trapped 4 He was not released. However, the 4 He released by deformation depended upon how the each rock deformed during deformation and the degree of grain size reduction. We postulate that 4 He precursor signals can be used to understand subsurface deformation only if geomechanical and geochemical conditions for 4 He enrichment in a lithology are met.

Deformation signals↗
DOE OSTI2021

Coupling dynamic in situ X-ray micro-imaging and indentation: A novel approach to evaluate micromechanics applied to oil shale

Oil and gas shales are a system where understanding the mechanical properties at the microscale is of paramount importance, e.g. to better understand the behavior of proppant-shale contacts and their role in the evolution of propped fractures in unconventional reservoirs. Here we show for the first time an experiment coupling indentation testing with in situ X-ray imaging in a Green River shale sample. A full compliance curve has been measured with the sample in water, allowing to visualize the indentation of the sample in function of axial load, in a purpose-built system for combined in situ indentation and X-ray imaging. A series of 3D datasets were used for a digital volume correlation study to obtain local strain fields. This analysis has been complemented with the analysis of cracks. Finally, geomechanical modeling has been carried out to replicate and generalize the observed behavior in the shale. This study validated this experimental approach, providing a breakthrough in understanding micro-mechanics in shales, and demonstrates how this class of experiments can be important for studies involving the prediction of the evolution of propped fractures in shale reservoirs, with possible applications in a much larger number of application fields (geothermal, materials science, etc.)

04 OIL SHALES AND TAR SANDS↗
DOE OSTI2022

Generalizability analysis of tool condition monitoring ensemble machine learning models

Tool condition monitoring (TCM) is an essential research area for the optimization and automation of metal machining processes, and could help manufacturers reduce costs, production time, machine downtime, energy use, and part scrappage. However, TCM systems developed in prior studies have struggled to reach the high level of generalizability which is necessary for industrial applications. This study addresses TCM system generalizability to new machining conditions, how variations in machining and environmental conditions may be used to improve model generalizability, and ensemble machine learning techniques for TCM. Further, milling tool life experiments were conducted using various machining conditions, and the processes' sound, spindle power, and axial load signals were collected. Different machine learning models were evaluated for the prediction of tool wear levels, including four individual models and five ensemble models. Changes in cutting speed were found to display a large effect on model performance, while the chip load showed some effect, and the feed rate had little effect. A simulated noise data augmentation technique for model improvement is applied within TCM for the first time, and resulted in increased model generalizability and reduced overfitting. Across several performance metrics the extremely randomized trees ensemble machine learning model generally performed the best for this application, achieving a leave-one-group-out cross validation accuracy score of 92.4 %, a 10-fold cross validation score of 98.9 %, and an averaged accuracy across 11 generalizability tests of 87.3 %.

42 ENGINEERING↗
DOE OSTI2020

TATB ratchet growth and hydrostatically-confined PBX 9502

The explosive TATB (1,3,5-triamino-2,4,6-trinitirobenzene) is formulated with various polymeric binders to create plastic-bonded explosives like PBX 9502 (95 wt% TATB and 5 wt% Kel-F binder). TATB crystals are graphitic and plate-like in nature and single crystals exhibit anisotropic thermal expansion where the direction normal to the platelet surface grows 10-20 times more than the in-plane platelet direction. Compactions of TATB, with and without binder, exhibit irreversible volume expansion, also known as ratchet growth, when thermal cycled to hot or cold temperatures. Specifically, when TATB-based compactions return to ambient after a temperature excursion away from room temperature, the volume of the specimen is slightly larger. Repeated thermal cycles can reduce the density by 1 to 2%. Axial confinement on a cylindrical specimen has previously been shown by us to suppress growth in the confining direction but then increase growth in the unconfined directions (likely due to creep effects). In the work presented here, PBX 9502 specimens were placed in cup assemblies where they were embedded in Sylgard (an incompressible silicon resin) to provide hydrostatic confinement when the assemblies were placed under different axial loads. The loaded cup assemblies were thermally cycled 10 times to hot and cold temperatures. Finally, results show that increasing the hydrostatic confining pressure causes a decrease in the PBX 9502 volume expansion that occurs.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Mjölnir: a miniature triaxial rock deformation apparatus for 4D synchrotron X-ray microtomography

An X-ray transparent experimental triaxial rock deformation apparatus, here named 'Mjölnir', enables investigations of brittle-style rock deformation and failure, as well as coupled thermal, chemical and mechanical processes relevant to a range of Earth subsurface environments. Designed to operate with cylindrical samples up to 3.2 mm outside-diameter and up to 10 mm length, Mjölnir can attain up to 50 MPa confining pressure and in excess of 600 MPa axial load. The addition of heaters extends the experimental range to temperatures up to 140°C. Deployment of Mjolnir on synchrotron beamlines indicates that full 3D datasets may be acquired in a few seconds to a few minutes, meaning full 4D investigations of deformation processes can be undertaken. Mjölnir is constructed from readily available materials and components and complete technical drawings are included in the supporting information.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

3D Mechanical Analysis of a Compact Nb 3 Sn IR Quadrupole for EIC

Abstract-The Electron Ion Collider (EIC) will require large aperture quadrupole magnets for the Hadron beam in the insertion region. Key requirements include high field, compact size, and tight control of the fringe fields. A 120 mm aperture, 308.4 mm outer diameter actively shielded Nb 3 Sn quadrupole model is under development to support these goals. This work is being carried out by a collaboration of BNL, JLAB and LBNL. A compact shell-based structure preloaded with a bladder and key system was developed for this project. In this paper, the effect of the compact structure on the mechanical behavior was investigated. In particular, the impact of the assembly tolerances and coil size variations on the actual coil stresses and bladder pressures was computed and compared with results from larger bladder and key structures developed for the LHC IR. The longitudinal preload is provided by stainless steel rods. Differently from other bladder and key magnets, the rods are first preloaded axially before coil axial load is applied. This new design aims to increase the overall stiffness of the system and reduce the longitudinal coil displacement during powering. Based on the results of a 3D mechanical analysis, the preliminary preload targets for the EIC quadrupole assembly will be reviewed and discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

Indirect Tool Condition Monitoring Using Ensemble Machine Learning Techniques

Abstract Tool condition monitoring (TCM) has become a research area of interest due to its potential to significantly reduce manufacturing costs while increasing process visibility and efficiency. Machine learning (ML) is one analysis technique which has demonstrated advantages for TCM applications. However, the commonly studied individual ML models lack generalizability to new machining and environmental conditions, as well as robustness to the unbalanced datasets which are common in TCM. Ensemble ML models have demonstrated superior performance in other fields, but have only begun to be evaluated for TCM. As a result, it is not well understood how their TCM performance compares to that of individual models, or how homogeneous and heterogeneous ensemble models’ performances compare to one another. To fill in these research gaps, milling experiments were conducted using various cutting conditions, and the model groups were compared across several performance metrics. Statistical t-tests were also used to evaluate the significance of model performance differences. Through the analysis of four individual ML models and five ensemble models, all based on the processes’ sound, spindle power, and axial load signals, it was found that on average, the ensemble models performed better than the individual models, and that the homogeneous ensembles outperformed the heterogeneous ensembles.

Engineering↗
DOE OSTI2023

PipeSight: A High-Performance Computing Platform for Pipeline Integrity Management

The Phase I feasibility study completed as part of this project has led to a number of innovative technologies being developed and has laid the foundation for a successful Phase II effort to commercialize a platform for managing the integrity of pipelines for the damage mechanisms of the new, hybrid-energy based economy. To ground the development efforts and direction of the project, an extensive market research and customer discovery effort was undertaken early in Phase I. Through this effort, a number of pipeline owners and operators were interviewed, and the following key findings were discovered about the pipeline industry: • Small pipeline operators do not have the central engineering groups necessary to perform their own independent analysis of inspection data, but instead rely on summarized tally sheets provided to them by inspection service providers. • The time it takes to go from an inspection to a completed engineering assessment, even for small segments of pipeline, can take anywhere from 30-120 days. During this delay, critical threats can (and have been known to) cause failures. • Uncertainty is often not accounted for in the assessment of pipeline integrity. The tally sheets provided by third-party service providers are almost always deterministic in nature, identifying threats that present a concern only to the current (not the future) integrity of the pipeline. • It is uncommon to apply the latest technologies to perform advanced assessments of damaged pipelines. There is a desire to use more advanced analysis capabilities to assess threats. Many pipeline operators indicated that they would often excavate a pipeline to perform an inspection and find that the damage was not as bad as they anticipated, thus using limited resources unnecessarily. Companies are not consistent in their use of inspection data to determine corrosion rates, and those that do only calculate deterministic corrosion rates. • The industry has prominently relied on time-based inspections but has recently started to transition to risk-based inspections. However, there appears to be no uniform guidance on how to do so while properly accounting for all sources of uncertainty. • Companies are not storing inspection data in a manner that allows for the ready determination of temporal trends. • Predictive maintenance principles and practices are beginning to be used by early adopters • Some pipelines are being re-purposed to transport different process fluids than they were designed for, e.g., H 2 and CO 2 rich process streams to serve the new hybrid-energy based economy, which are presenting new integrity concerns for the existing pipeline network that crisscrosses the United States. As a result of these discoveries, we were able to target the development efforts in Phase I to best serve the needs of the industry. In Phase I, we developed a way to correlate multiple large-scale scans of the pipeline to determine a probabilistic corrosion rate that accounts for all sources of error and uncertainty in the inspection process. This probabilistic corrosion rate can be used to predict the future thickness distribution of the pipe wall. We demonstrate how this analysis may be performed in an analytical fashion and has been implemented in such a manner that it can be readily distributed using GPU computing through integration of the Kokkos programming model. We also make a very novel extension of the analytical corrosion rate model to Bayesian Networks (an explainable AI technique) that can account for non-parametric distributions of corrosion rates. With the predictions made above for the probabilistic corrosion rate and corresponding future distribution of the pipe wall thickness, we can assess the integrity of the pipeline through the use of a probabilistic engineering assessment. We developed a novel screening data analysis approach that can rapidly identify ‘hotspots’ (local thin areas) where the integrity of the pipeline is a concern. Once more, we implemented this screening approach in C++ to leverage GPU computing via the Kokkos programming model. After the critical hotspots are identified, we developed a program that can automatically generate an advanced finite element model of the damaged regions. Since the number of damaged regions that require advanced analysis can number in the thousands, we integrated an open-source container-native workflow engine for orchestrating parallel jobs on the cloud. Initially, these advanced numerical models were only designed to account for loading due to internal pressure. However, in a slight pivot from the initial Phase I proposal, we developed a complete pipe stress analysis program (called Simflex) which can simulate the complete pipeline and its response to thermal expansion, pressure, thermal bowing, weight, wind, earthquake, support displacement, support friction and external forces. This pipe stress analysis program was written generically, to handle any piping system, but contains the features needed to model long pipelines (i.e., it incorporates a model for soil mechanics and can account for the nonlinear boundary conditions necessary to simulate long underground pipelines). This pipe stress analysis program can simulate any segment of the pipeline (simple or complex) under any set of conditions and loads, to determine the supplemental loads (axial forces and bending moments) at the location of damage. This enables the most accurate state of stress to be accounted for in the pipeline, which can prove critical when evaluating the integrity of a damaged region. In the process of developing the technologies to perform the integrity assessment of the pipeline, we also extended one of the industry standard approaches for performing the assessment of local thin areas that extend more in the circumferential direction than the longitudinal direction of the pipeline. This approach was presented to the API 579-1/AS ME FFS-1 steering committee in November 2021 for consideration in the next edition of the industry standard for Fitness-For-Service (expected to be released in 2023). To help pipeline operators make decisions with the results on any integrity assessment, we developed a new approach to the life-cycle management of pipelines which uses a Bayesian Decision Network. The network is designed to help pipeline operators plan and prioritize inspection activities and ultimately make smarter, more cost-effective decisions. The Bayesian approach accounts for all sources of uncertainty and carries them through to the final optimal decisions, providing a probabilistic framework for optimizing inspection intervals. The proof-of-concept networks developed in the feasibility study are complete, verified, and are focused on a subset of the pipeline. To expand this novel approach to the scale necessary for an entire network of pipelines in Phase II, we will leverage the DOE-funded Bengi solver for industrial-scale decision making with Bayesian Networks [22]. Once implemented, we will be able to provide the pipeline industry with a much-needed tool for optimal inspection planning using truly explainable artificial intelligence (XAI). To handle all of these advanced capabilities into a cloud-based platform, the architecture of the Equity Engineering Cloud (EEC) was extended to include Argo Workflows, a framework capable of distributing and managing a massive number of jobs that consume their own resources, such that thousands of serial finite element simulations can be run in parallel. As part of this substantial undertaking, we also integrated Argo Continuous Delivery (CD) into the EEC, to aid with the rapid prototyping and iterations that will be imperative to the success of the PipeSight platform’s Agile development process in Phase II. As part of the pipe stress analysis program, we also developed a custom visualizer that leverages the DOE-funded VTK visualization library. We added custom contouring capabilities and a means for interacting visually with both the inputs and outputs of the pipe stress analysis program. We also developed routines for automating the post-processing of the finite element simulations to determine if any failure criteria are met and to visualize the deformations, stresses and strains in ParaView using the exodus II file format (a subset of netCDF).

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Modular anti-rotation drilling systems and methods

Drilling tools are frequently subject to rotation with respect to the central drilling axis caused by torque. A mechanical linkage can be configured to apply force that is proportional to the weight-on-bit on the borehole surface while transmitting axial loads used to generate weight-on-bit. The device can be used to manage drill string twist that could lead to drilling dysfunctions.

Su, Jiann-Cherng↗
DOE OSTI2022

Computational Modeling of Multi-Pass Rolling Parameters Effect on Resulting Fuel Foil Shape

A focus of the U.S. Department of Energy is to improve production yield and reduce the cost of Low Enriched Uranium (LEU)-molybdenum alloy (U-10Mo) monolithic fuel plates that will be replacing High Enriched Uranium (HEU) oxide dispersion fuels used currently in the United States High Performance Research Reactors (USHPRR). One area of improvement is lowering the high transverse waviness and longitudinal waviness currently present within rolled foils prior to cladding to produce fuel plates. Traditional rolling manufacturing techniques for other metal foils use winders to pull and straighten the foil as it is rolled back and forth to the final thickness. This approach cannot be used to roll thin U-10Mo foils (0.008-0.025” thick) because only small castings can be rolled due to nuclear criticality safety concerns. As a result, the fuel foils are too short (1 m in length) to use traditional winders. Therefore, it is crucial to identify other rolling parameters (i.e., roller friction, axial tension load, roller diameter, and roll pass reduction percent) that might reduce transverse waviness and longitudinal waviness in the rolled fuel foil and develop a high-yield, low-cost multi-pass rolling manufacturing process. This report documents a systematic finite element modeling study to investigate the effects of numerous rolling parameters to reduce resulting transverse waviness and longitudinal waviness in the fuel foil during multi-pass rolling of U-10Mo foils. The rolling of a U-10Mo plate with initial dimensions of 1”x1”x 0.048” is modeled using Abaqus CAE. This rolling is modeled to undergo eight 20% reduction roll passes to a final fuel foil thickness of 0.01”. The elastic-plastic constitutive model of the U-10Mo alloy was input to the fuel foil rolling model. The rollers were modeled as rigid bodies. A comparison of rolling friction coefficients of 0.3 and 0.7 over a wide range of applied axial tension loads were investigated in order to evaluate the effect of using a lubricant during rolling. The effect of roller diameter on the resulting transverse waviness and longitudinal waviness of the fuel foil over a wide range of axial tension loads were also investigated by modeling rollers 7/8” and 3.75” in diameter. The results of this systematic finite element method study will aid manufacturers in producing low transverse waviness and reduced longitudinal waviness in U-10Mo fuel foils.

U-10Mo, FEA, Rolling, Residual Stress, Fuel Foil↗
DOE OSTI2022

Prediction of strain, inter-layer interaction and critical current in CORC ® wires under axial strain by T-A modeling

Superconducting conductors on round core (CORC ® ) cables and wires can meet the needs of large high-field magnets, such as particle accelerators and compact nuclear fusion machines, due to their simple cabling process, high current-carrying capacity and reliable operation under high mechanical stresses. Many high-field magnets require CORC ® cables to carry a current of thousands of amperes in a background magnetic field exceeding 20 T. As a result, the large electromagnetic forces will deform the cable in the axial direction due to hoop stress and in the transverse direction by compressive stress. Therefore, it is essential to determine the irreversible deformation limit of the CORC ® cable under axial tensile load and optimize the cabling parameters to potentially extend this limit. Analytical and numerical methods are developed to assess the performance degradation of CORC ® wires under axial tensile load. The strain level, interlayer contact pressure and friction and their impact on the critical current are calculated by combining the mechanical response and the T-A method. Analyzing the results shows that the winding angle of the tape and the Poisson’s ratio of the inner core are key factors affecting the irreversible tensile strain limit of CORC ® wires. The smaller the winding angle and the higher the Poisson’s ratio of the inner core, the higher the irreversible tensile strain limit. For multi-layer CORC ® wires, the initial contact pressure caused by the cabling process must also be considered. The inter-layer interaction is coupled with the tape strain of each layer. The results of this research can serve as a basis for optimizing and designing CORC ® wires with extended irreversible strain limits.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

A novel approach for tetrahedral-element-based finite element simulations of anisotropic hyperelastic intervertebral disc behavior

Intervertebral discs are microstructurally complex spinal tissues that add greatly to the flexibility and mechanical strength of the human spine. Attempting to provide an adjustable basis for capturing a wide range of mechanical characteristics and to better address known challenges of numerical modeling of the disc, we present a robust finite-element-based model formulation for spinal segments in a hyperelastic framework using tetrahedral elements. We evaluate the model stability and accuracy using numerical simulations, with particular attention to the degenerated intervertebral discs and their likely skewed and narrowed geometry. To this end, 1) annulus fibrosus is modeled as a fiber-reinforced Mooney-Rivlin type solid for numerical analysis. 2) An adaptive state-variable dependent explicit time step is proposed and utilized here as a computationally efficient alternative to theoretical estimates. 3) Tetrahedral-element-based FE models for spinal segments under various loading conditions are evaluated for their use in robust numerical simulations. For flexion, extension, lateral bending, and axial rotation load cases, numerical simulations reveal that a suitable framework based on tetrahedral elements can provide greater stability and flexibility concerning geometrical meshing over commonly employed hexahedral-element-based ones for representation and study of spinal segments in various stages of degeneration.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

MECHANICAL PERFORMANCE EVALUATION OF THE PRINTED CIRCUIT HEAT EXCHANGER CORE EXPERIMENTS UNDER TENSION AND PRESSURE LOADING

The printed circuit heat exchanger (PCHE) has small channels with high surface area, making them an efficient solution for next-generation nuclear plants (NGNPs). These PCHEs are fabricated through a diffusion bonding process. This fabrication step changes the microstructure of wrought metal plates. The current ASME design code does not support the PCHE design for NGNPs due to a lack of test data. Hence, there has been initiative towards elevated temperature mechanical property characterization of the diffusion bonded material. One of the most common channel shapes is a semicircular channel with sharp corners. These corners act as a stress riser at the diffusion bonding interface. Evaluating elevated temperature mechanical performance of diffusion bonded material in the presence of stress risers is an essential step towards the ASME code development of PCHE design. This study selected two specimen geometries: the first is a PCHE bar specimen for tensile loading with three rows and three columns of channels, and the second is a lab-scaled PCHE with six rows and eight columns of channels. A set of elevated temperature monotonic and cyclic tests were conducted on the PCHE bar specimen to evaluate the mechanical performance under axial tensile loadings to study the failure mechanism. The lab-scaled PCHE specimens were tested under overpressure loads at room temperature, and pressure creep and pressure creep-fatigue loadings to mimic the realistic loading conditions observed in typical NGNPs. The X-ray scans of channeled specimens show interesting observations. The test results and observations are presented in the paper.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Analytical models of the strength and ductility of CNT reinforced metal matrix nano composites under elevated temperatures

Carbon nanotubes (CNTs) can greatly enhance the strength of metal matrix composites while resulting in ductility loss. This strength-ductility tradeoff dilemma always confines the development of material design and real-life applications. Here in this work, a temperature dependent strengthening analytical model is proposed for CNT reinforced metal matrix composites which considers three common strengthening mechanisms: Orowan looping effect, thermal expansion mismatch effect, and load bearing effect. The proposed model can predict composite material strength with different volume fractions of CNTs and under different temperatures. Combining the strengthening model with the stress based modified Mohr-Coulomb (sMMC) ductile fracture model, a ductility analytical model is then derived. This ductility analytical model includes the influences of temperature, multi-axial stress loading conditions, as well as the aforementioned three strengthening mechanisms. A good agreement has been achieved between literature published experimental data and analytical predictions for both composite material strength and ductility loss. The proposed two analytical models can provide a straightforward way to study the strength-ductility relationship for CNT reinforced metal matrix composites over a wide range of temperatures and different stress states, and then provide guidance on new material design and processing.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Structural integrity of additively manufactured stainless steel with cold sprayed barrier coating under combined cyclic loading

Integration of metal additive manufacturing (AM) and cold spray (CS) technologies provide an unprecedented opportunity to manufacture coated material systems with complex geometrical features. The application of these material systems in functionally critical components requires adequate structural integrity, particularly in the presence of cyclic loading. This article researches the multiaxial fatigue (axial-torsional cyclic loading) behavior of a coated material system consisting of 15Cr-5Ni precipitation-hardening stainless steel (15-5 PH SS) substrate additively manufactured by direct metal laser sintering with a layer of chromium carbide nickel (CrC-Ni) barrier coating deposited by CS. The influence of AM and CS-induced residual stresses on fatigue performance of test specimens was thoroughly studied. Additionally, the effect of surface roughness and processes induced defects were considered to explain the crack growth mechanism. Stresses assessed by synchrotron X-ray diffraction indicated a substantial accumulation of residual stresses, particularly in the outer surface of the as-fabricated 155 PH SS specimens. The state of residual stress was changed notably following the deposition of CrC-Ni coating in the axial, hoop, and radial directions of the fatigue test specimen. Also, CS deposition of CrC-Ni coating caused significant improvement in the surface quality of the additively manufactured components. Fatigue test results indicated, CS deposition of CrC-Ni substantially enhances the fatigue life of the AM-produced 15-5 PH SS substrate in all loading conditions, particularly in the high cycle fatigue regime. The improvement in the fatigue life of the specimens with coating was associated with a reduction in equivalent residual stress at the substrate surface and improvement in the specimens' surface condition (i.e., reduced surface roughness). The fractographic analysis of the specimen indicated the cracks tend to initiate in the surface of both as-fabricated and cold-sprayed specimens. However, the mechanism of crack growth changed notably following the deposition of CrC-Ni coating. The cracks tended to propagate in the planes parallel or with a small deviation from the build layers of the AM-produced specimens. On the other hand, deposition of CrC-Ni coating increased the deviation of crack growth plane from the build layers of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A System-Level Model for Estimating Residual Strain and Life of Nuclear Reactor Coolant System Components Under Connected-System-Thermal–Mechanical Boundary Conditions

Background: Environmental-assisted fatigue (EAF) is a major issue for the long-term survival of nuclear power plant fleets in the U.S. and worldwide. Multi-material welded regions (e.g., nozzles) and other high-stress regions of reactor coolant system (RCS) components are prone to EAF-related damage. Objective: The discussed work describes a system-level finite element (FE) model of RCS components of a pressurized water reactor (PWR). This is with the goal of predicting the stress hotspots, strain residuals, strain amplitudes and the resulting fatigue lives. Methods: Herein, the FE model was developed considering system-level loading conditions (under connected system thermal-mechanical boundary conditions). Thermal-mechanical stress analysis was performed considering thermal stratification and a design-basis reactor loading cycle. Based on the FE model results, the strain residuals, strain amplitudes and resulting fatigue lives of RCS components were predicted. Results: The results show that some of the RCS components can have significantly different strain amplitudes, residual strain, and fatigue lives, despite having similar geometry and material. Higher residual strain can lead to accelerated cyclic hardening of material and the associated effect of EAF. The simulated component-level strain profile (under realistic multi-axial-multi-physics loading cycle) can guide the selection of appropriate test inputs for conducting laboratory-scale EAF tests, which is a focus of future works. Conclusions: Despite similar geometry and material the RCS component can have significantly different strain profiles and resulting fatigue lives. The discussed approach can help to identify and prioritize the RCS components for conducting expensive nondestructive evaluation (NDE) inspections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

AI-based design of a nuclear reactor core

The authors developed an artificial intelligence (AI)-based algorithm for the design and optimization of a nuclear reactor core based on a flexible geometry and demonstrated a 3× improvement in the selected performance metric: temperature peaking factor. The rapid development of advanced, and specifically, additive manufacturing (3-D printing) and its introduction into advanced nuclear core design through the Transformational Challenge Reactor program have presented the opportunity to explore the arbitrary geometry design of nuclear-heated structures. The primary challenge is that the arbitrary geometry design space is vast and requires the computational evaluation of many candidate designs, and the multiphysics simulation of nuclear systems is very time-intensive. Therefore, the authors developed a machine learning-based multiphysics emulator and evaluated thousands of candidate geometries on Summit, Oak Ridge National Laboratory’s leadership class supercomputer. The results presented in this work demonstrate temperature distribution smoothing in a nuclear reactor core through the manipulation of the geometry, which is traditionally achieved in light water reactors through variable assembly loading in the axial direction and fuel shuffling during refueling in the radial direction. The conclusions discuss the future implications for nuclear systems design with arbitrary geometry and the potential for AI-based autonomous design algorithms.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗