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DOE OSTI2016

Modeling the measured effect of a nitroplasticizer (BDNPA/F) on cookoff of a plastic bonded explosive (PBX 9501)

Here, we have used a modified version of the Sandia Instrumented Thermal Ignition (SITI) experiment to develop a pressure-dependent, five-step ignition model for a plastic bonded explosive (PBX 9501) consisting of 95 wt% octahydro-1,3,5,7-tetranitro-1,3,5,7-tetrazoncine (HMX), 2.5 wt% Estane® 5703 (a polyurethane thermoplastic), and 2.5 wt% of a nitroplasticizer (NP): BDNPA/F, a 50/50 wt% eutectic mixture bis(2,2-dinitropropyl)-acetal (BDNPA) and bis(2,2-dinitropropyl)-formal (BDNPF). The five steps include desorption of water, decomposition of the NP to form NO2, reaction of the NO2 with Estane® and HMX, and decomposition of HMX. The model was fit using our experiments and successfully validated with experiments from five other laboratories with scales ranging from about 2 g to more than 2.5 kg of PBX. Our experimental variables included density, confinement, free gas volume, and temperature. We measured internal temperatures, confinement pressure, and ignition time. In some of our experiments, we used a borescope to visually observe the decomposing PBX. Our observations included the endothermic β–δ phase change of the HMX, a small exothermic temperature excursion in low-density unconfined experiments, and runaway ignition. We hypothesize that the temperature excursion in these low density experiments was associated with the NP decomposing exothermically within the PBX sample. This reactant-limited temperature excursion was not observed with our thermocouples in the high-density experiments. For these experiments, we believe the binder diffused to the edges of our high density samples and decomposed next to the highly conductive wall as confirmed by our borescope images.

42 ENGINEERING↗

NASA NTRS1973

A high-speed photographic system for flow visualization in a steam turbine

A photographic system was designed to visualize the moisture flow in a steam turbine. Good performance of the system was verified using dry turbine mockups in which an aerosol spray simulated, in a rough way, the moisture flow in the turbine. Borescopes and fiber-optic light tubes were selected as the general instrumentation approach. High speed motion-picture photographs of the liquid flow over the stator blade surfaces were taken using stroboscopic lighting. Good visualization of the liquid flow was obtained. Still photographs of drops in flight were made using short duration flash sources. Drops with diameters as small as 30 micrometers (0.0012 in.) could be resolved. In addition, motion pictures of a spray of water simulating the spray off the rotor blades and shrouds were taken at normal framing rates. Specially constructed light tubes containing small tungsten-halogen lamps were used. Sixteen millimeter photography was used in all cases. Two potential problems resulting from the two-phase turbine flow (attenuation and scattering of light by the fog present and liquid accumulation on the borescope mirrors) were taken into account in the photographic system design but not evaluated experimentally.

Barna, G. J.↗

NASA NTRS1988

Sizing Dye-Penetrant Indications Of Defects

Sizes of cracks and holes viewed through borescope measured. Reference chart makes it possible to estimate sizes of borescope-observed defects on inner walls of tubes or otherwise hidden. Used both for round defects like pits or pores and for elongated ones like cracks.

Molina, Orlando G.↗

NASA NTRS2001

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2002

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB (Solid Rocket Booster). TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly. to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2003

Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware

USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC / solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.

Novak, Howard L.↗

NASA NTRS2016

Demonstration of a Packaged Capacitive Pressure Sensor System Suitable for Jet Turbofan Engine Health Monitoring

In this paper, the development and characterization of a packaged pressure sensor system suitable for jet engine health monitoring is demonstrated. The sensing system operates from 97 to 117 MHz over a pressure range from 0 to 350 psi and a temperature range from 25 to 500 deg. The sensing system consists of a Clapp-type oscillator that is fabricated on an alumina substrate and is comprised of a Cree SiC MESFET, MIM capacitors, a wire-wound inductor, chip resistors and a SiCN capacitive pressure sensor. The pressure sensor is located in the LC tank circuit of the oscillator so that a change in pressure causes a change in capacitance, thus changing the resonant frequency of the sensing system. The chip resistors, wire-wound inductors and MIM capacitors have all been characterized at temperature and operational frequency, and perform with less than 5% variance in electrical performance. The measured capacitive pressure sensing system agrees very well with simulated results. The packaged pressure sensing system is specifically designed to measure the pressure on a jet turbofan engine. The packaged system can be installed by way of borescope plug adaptor fitted to a borescope port exposed to the gas path of a turbofan engine.

Harsh environment↗

DOE OSTI2015

Miniature motorized inspection tool for DOE Hanford site tank bottoms - 15700

Recently, small amounts of waste have been found in the annulus of tank AY-102, prompting the need for developing inspection tools that can identify the cause and location of the leak. Three separate access paths can be used to obtain information regarding the tank bottom condition. The inspection may be conducted via: 1) Refractory air slots through the annulus; 2) 4'' annulus air supply pipe to central air slots; 3) 6'' leak detection pit drain from the central sump. There are various environmental and physical constraints which the tool will have to adhere to. In order for the tool to be successful, it must be capable of the following: Travel through small cooling channels with dimensions as small as 1.5'' x 1.5''; Provide live video feedback; Produce enough torque to overcome the tether drag force; Inverted travel to avoid obstacles such as tank corrosion; Navigate up to 38 feet to the tank center, while maneuvering through four 90 deg. turns. A model of the inspection tool has been designed, assembled and reported. Areas of potential performance improvement were observed; these areas are the basis of the following design, as seen above. The changes include: The addition of an additional 4 wheels; Body modification to house the camera; A loft on the bottom from the tools edge to the magnets lowest edge; Shaving the hubs of the current wheels; Control method changed to a joystick. The tank configuration through which the tool will have to maneuver are the following: 72 outer ring slots (1.5'' x 1.5'' x 17'); 36 ring slots (2'' x 1.5'' x 12'); 18 inner slots (3'' x 1.5'' x 7'). The components used for this design iteration are not radiation hardened nor are they designed to withstand elevated temperatures. However, this prototype has been constructed with the final goal of being radiation hardened and able to withstand elevated temperatures in mind. The components that make up this design iteration are the following: Arduino Uno board with ATMega328 micro-controller; Joystick shield kit for the Arduino Uno; Eggsnow USB Borescope Endoscope 5.5 mm inspection camera; 136:1 Sub-micro Plastic Planetary Gearmotor; 14 x 4.5 mm wheels; 3D-printed body; 3D-printed free rolling shafts; Neodymium magnet - 1 h x 3/8 h x 1/16 h; 4.53 lb pull force. In the time to come, there are a few goals that are to be completed. The first group of tasks is associated with the testing and recording of data of the current prototype. This data will be analyzed and appropriate action will be taken based on the results of the testing. The testing will include simulating the challenges that the tool will face in the AY-102 tank. Working with the Hanford DOE site, a bag of Kaolin 2200 will be acquired to be used for the test bed to simulate tank conditions. Further modification will then be made to enable the tool to be able to maneuver through a 90 deg. turn. Completion of this task will be a major milestone, as this tool will be readily usable in the other tanks containing HLW; as other tanks will be easier to maneuver through.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2017

Void fraction, bubble size and interfacial area measurements in co-current downflow bubble column reactor with microbubble dispersion

Micro-bubbles dispersed in bubble column reactors have received great interest in recent years, due to their small size, stability, high gas-liquid interfacial area concentrations and longer residence times. The high gas-liquid interfacial area concentrations lead to high mass transfer rates compared to conventional bubble column reactors. In the present work, experiments have been performed in a down-flow bubble column reactor with micro-bubbles generated and dispersed by a novel mechanism to determine the gas-liquid interfacial area concentrations by measuring the void fraction and bubble size distributions. Gamma-ray densitometry has been employed to determine the axial and radial distributions of void fraction and a high speed camera equipped with a borescope is used to measure the axial and radial variations of bubble sizes. Also, the effects of superficial gas and liquid velocities on the two-phase flow characteristics have been investigated. Further, reconstruction techniques of the radial void fraction profiles from the gamma densitometry's chordal measurements are discussed and compared for a bubble column reactor with dispersed micro-bubbles. The results demonstrate that the new bubble generation technique offers high interfacial area concentrations (1,000 to 4,500 m 2 /m 3 ) with sub-millimeter bubbles (500 to 900 µm) and high overall void fractions (10% – 60%) in comparison with previous bubble column reactor designs. The void fraction data was analyzed using slip velocity model and empirical correlation has been proposed to predict the Sauter mean bubble diameter.

09 BIOMASS FUELS↗

DOE OSTI2018

Large deformation and gas retention during cookoff of a plastic bonded explosive (PBX 9407)

Here, we have used several configurations of the Sandia Instrumented Thermal Ignition (SITI) experiment to develop a pressure-dependent, four-step ignition model for a plastic bonded explosive (PBX 9407) consisting of 94 wt.% RDX (hexahydro-1,3,5-trinitro-1,3,5-triazine), and a 6 wt.% VCTFE binder (vinyl chloride/chlorotrifluoroethylene copolymer). The four steps include desorption of water, decomposition of RDX to form equilibrium products, pressure-dependent decomposition of RDX forming equilibrium products, and decomposition of the binder to form hydrogen chloride and a nonvolatile residue (NVR). We address drying, binder decomposition, and decomposition of the RDX component from the pristine state through the melt and into ignition. We used Latin Hypercube Sampling (LHS) of the parameters to determine the sensitivity of the model to variation in the parameters. We also successfully validated the model using one-dimensional time-to-explosion (ODTX and P-ODTX) data from a different laboratory. Our SITI test matrix included 1) different densities ranging from 0.7 to 1.63 g/cm 3 , 2) free gas volumes ranging from 1.2 to 38 cm 3 , and 3) boundary temperatures ranging from 170 to 190 °C. We measured internal temperatures using embedded thermocouples at various radial locations as well as pressure using tubing that was connected from the free gas volume (ullage) to a pressure gauge. We also measured gas flow from our vented experiments. A borescope was included to obtain in situ video during some SITI experiments. We observed significant changes in the explosive volume prior to ignition. Our model, in conjunction with data observations, imply that internal accumulation of decomposition gases in high density PBX 9407 (90% of the theoretical maximum density) can contribute to significant strain whether or not the experiment is vented or sealed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

Cookoff experiments of a melt cast explosive (Comp-B3)

Validated models of melt cast explosives exposed to accidental fires are essential for safety analysis. In the current work, we provide several experiments that can be used to develop and validate cookoff models of melt cast explosives such as Comp-B3 composed of 60:40 wt% RDX:TNT. We present several vented and sealed experiments from 2.5 mg to 4.2 kg of Comp-B3 in several configurations. We measured pressure, spatial temperature, and ignition time. Some experiments included borescope images obtained during both vented and sealed decomposition. We observed the TNT melt, the suspension of RDX particles in the melt, bubble formation caused by RDX decomposition, and bubble-induced mixing of the suspension. The RDX suspension did not completely dissolve, even as temperatures approached ignition. Our results contrast with published measurements of RDX solubility in hot TNT that suggest RDX would be completely dissolved at these high temperatures. These different observations are attributed to sample purity. We did not observe significant movement of the two-phase mixture until decomposition gases formed bubbles. Bubble generation was inhibited in our sealed experiments and suppressed mixing.

42 ENGINEERING↗

DOE OSTI2022

Characterization of Saltstone Grout Line Samples

During a prestart recirculation operation in the Saltstone Processing Facility (SPF), operations staff noticed hardened scaling falling into the hopper. As a result, SPF operators and Saltstone Engineering decided to postpone operation and conduct a process room hopper cleanout. During the cleanout effort personnel noted greater than normal buildup of damp solid material in the transfer line. A borescope investigation was conducted and confirmed buildup was present throughout the transfer line to the downstream valves. Savannah River National Laboratory personnel were asked to characterize the scale material and samples collected from the saltstone grout line and provide recommendations and/or further guidance as to whether additional corrosion testing is needed for useful equipment operating life information. Based on the samples characterized results, the plug material contained only the 60:40 slag:fly ash saltstone. Portland cement in the original 10:45:45 Portland cement:slag:fly ash mix may result in a less abrasive slurry compared to the 60:40 slag:fly ash mix because the slag is > 95 % crushed angular, sharp edged glass. Saltstone grout erosion and corrosion testing of A36 carbon steel is needed to determine if the 60:40 mix is more abrasive and corrosive for A36 carbon steel than the 10:45:45 mix.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

The effect of inhomogeneities in coal-based mesophase pitch on filament formation and melt spinning for carbon fiber

Mesophase pitch-based carbon fibers excel as high specific strength and modulus materials, but challenges in stable, continuous melt spinning processing are a serious limiting factor. Inhomogeneities in the pitch may result in flow instabilities that can lead to filament breakage. This work aims to characterize and offer mitigation strategies for the negative effects that inhomogeneities such as isotropic binder, gels, and other inclusions impart on melt spinning of mesophase pitch. The effect of inhomogeneities on spinning stability are analyzed using capillary rheometry, borescope imaging of elongating filaments, and filtration. With no filter, immediate blockage of the spinning capillary occurred. Improvement in melt spinning duration was observed when a porous metal filter (20 μm nominal pore size) was utilized, but no significant further improvement in spinning duration was found upon decreasing the filter nominal pores size to 10, 5 and 2 μm. Moreover, flow instabilities that disrupted melt spinning stability were observed by capillary rheometry when the size of included isotropic pitch domains were larger than approximately 10 μm. Resultant carbon fiber properties and SEM imaging of fracture surfaces are reported.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1988

Programmable Grit-Blasting System

In programmable grit-blasting system undergoing design, controller moves blasting head to precise positions to shape or remove welding defects from parts. Controller holds head in position for preset dwell time and moves head to new position along predetermined path. Position of articulated head established by pair of servomotors according to programmed signals from controller. Head similar to video borescope. Used to remove welding defects in blind holes. Suited for repetitive production operations in grit-blast box.

Burley, Richard K.↗

NASA NTRS1990

Visual-Inspection Probe For Cryogenic Chamber

Visual-inspection probe that resembles borescope enables observer at ambient temperature to view objects immersed in turbulent flow of liquid oxygen, liquid nitrogen, or other cryogenic fluid. Design of probe fairly conventional, except special consideration given to selection of materials and to thermal expansion to provide for expected range of operating temperatures. Penetrates wall of cryogenic chamber to provide view of interior. Similar probe illuminates scene. View displayed on video monitor.

Friend, Steve↗

NASA NTRS1990

Inspecting The Full Circumferences Of Tubes

Proposed tool for inspection of external welds on tube gives view of full circumferential strip of outer surface. Similar to borescopes used to inspect interiors of tubes. Instead of fitting inside tube, new tool encircles it. Inspection more reliable and less time consuming.

Geddes, John P.↗

NASA NTRS1991

Lighted, Folding Inspection Mirror

Compact, inexpensive tool used in place of expensive borescopes. Shortens inspection/photographing process. Includes two small metal or glass mirrors hinged together. Two 3-V light bulbs attached along edges of one mirror and connected to battery of two cells. Inserted into narrow opening of clevis or tand, and surface viewed and photographed in opposite mirror. Useful in assembly of segments of solid rocket motors as well as in postflight assessment, engineering evaluation, and refurbishment. Also applied in general to inspection and photographing of inner sealing surfaces to which access difficult.

Roepe, Brian E.↗

NASA NTRS1991

Ames Research Center C-130

The C130 Earth Resources Aircraft provides a platform for a variety of sensors that collect data in support of terrestrial and atmospheric projects sponsored by NASA in coordination with Federal, state, university, and industry investigators. This data is applied to research in the areas of forestry, agriculture, land use and land cover analysis, hydrology, geology, photogrammetry, oceanography, meteorology, and other earth science disciplines. The C130 is a platform aircraft flying up to 25,000 feet above sea level at speeds between 150 and 330 knots True Air Speed. The aircraft is capable of precise flight line navigation by means of an optical borescope from which line guidance is provided to the pilots.

Koozer, Mark A.↗