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Development of Multilayered Coatings for Nerva-Type Graphite Fuel Elements- An Overview

“Mid-passage corrosion” (MPC) was observed in NbC and ZrC-coated graphite (Gr)-based nuclear fuels during the NERVA/Rover programs. A new multilayered coating concept was proposed to solve this problem. The concept envisions designing a compliant multilayered coatings architecture to accommodate the thermal expansion mismatch strains between the ZrC outer coating and the Gr/(U,Zr)C fuel matrix. Additionally, the coating architecture uses diffusion barriers to minimize carbon diffusion from the substrate, and hydrogen diffusion from the flowing gas stream, into the multilayer coating. The present paper provides a brief overview of the development of multilayered coatings deposited on Gr disks, as well as within the inner channels of a19-hole hexagonal rod 152.4 mm long, by chemical vapor deposition (CVD) in proof-of concept studies. The cross-sectional microstructural observations are discussed. These trials have established that it is possible to deposit multilayered coatings by CVD in 19-hole hexagonal rods similar to the NERVA fuel rod design although the quality of the coatings and the uniformity of their thicknesses require further improvement.

Multilayer coatings, graphite, nuclear thermal pro↗

NASA NTRS2018

Study of a Tricarbide Grooved Ring Fuel Element for Nuclear Thermal Propulsion

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nu- clear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the operating temperature of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment. Results of experiments and associated analysis are desired densities with some success in material distribution and reaching a solid solution. Future work is needed to improve distribution of material, minimize oxidation during the milling process, and de ne a fabrication process that will serve for constructing grooved ring fuel rods for large system tests.

Taylor, Brian↗

NASA NTRS2018

Study of a Tricarbide Grooved Ring Fuel Element for Nuclear Thermal Propulsion

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nuclear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the operating temperature of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment. Results of experiments and associated analysis are discussed. The authors demonstrated success in reaching desired densities with some success in material distribution and reaching a solid solution. Future work is needed to improve distribution of material, minimize oxidation during the milling process, and define a fabrication process that will serve for constructing grooved ring fuel rods for large system tests.

Taylor, Brian↗

NASA NTRS1977

Nuclear thermionic converter

Efficient nuclear reactor thermionic converter units are described which can be constructed at low cost and assembled in a reactor which requires a minimum of fuel. Each converter unit utilizes an emitter rod with a fluted exterior, several fuel passages located in the bulges that are formed in the rod between the flutes, and a collector receiving passage formed through the center of the rod. An array of rods is closely packed in an interfitting arrangement, with the bulges of the rods received in the recesses formed between the bulges of other rods, thereby closely packing the nuclear fuel. The rods are constructed of a mixture of tungsten and thorium oxide to provide high power output, high efficiency, high strength, and good machinability.

Phillips, W. M.↗

NASA NTRS2021

Microstructural Observations on Advanced Multilayer Protective Coatings for Nuclear Thermal Propulsion

The present research discusses the microstructures of a new multilayered coating concept proposed to solve the “midrange corrosion” problem observed in NbC and ZrC-coated graphite (Gr) nuclear fuels during the NERVA/Rover programs. The concept envisions designing a compliant multilayered coatings architecture to accommodate the thermal expansion mismatch strains between the ZrC outer coating and the Gr/(U,Zr)C fuel matrix along with using a diffusion barrier to minimize carbon and hydrogen diffusion, respectively. Multilayered coatings were deposited on Gr substrates by chemical vapor deposition (CVD). Graphite disks, as well as the inner channels of a 19-hole hexagonal rod 152.4 mm long, were coated by CVD in proof-of concept process demonstration studies. Coated disk specimens were thermally-cycled between ambient and 1900 K for as long as 20 cycles with a 1h hold time at the temperature using both stepped and non-interrupted thermal cycling methods. Detailed cross-sectional microstructural analyses were conducted on the thermally-cycled coated disks. These results showed that the coatings were intact after 20 thermal cycles at 1900 K although the bonding of the overlay Mo coating appeared to be influenced by the oxygen content in the layer. Seven transverse sections were cut along the length from the coated hexagonal rod for microstructural studies. All the nineteen channels were observed to have been coated in all the sections. This paper reports the results of detailed microstructural analyses, compositional line scans and x-ray dot maps conducted on three coated channels from a mid-section of the rod. The measured values of carbon (C) were observed to be exceptionally high in all the specimens, which were attributed to hydrocarbon contamination of the specimen surfaces. It was observed that the oxygen (O) levels were high in all the coating layers even after approximately correcting for the observed high values of C. The source of O contamination of the CVD reactor system was attributed to either the presence of oxychloride impurities in the precursor salts or a pin hole leak in the coating system. It is concluded that high values of O result in poor bonding of the Mo overlay to the ZrC layer. These trials have established that it is possible to deposit multilayered coatings by CVD in 19-hole hexagonal rods 152.4 mm long similar to the NERVA fuel rod design although the quality of the coatings and the uniformity of their thicknesses require further improvement.

Nuclear thermal propulsion, multilayer coatings, m↗

NASA NTRS1973

Fast-spectrum space-power-reactor concepts using boron control devices

Several fast-spectrum space power reactor concepts that use boron carbide control devices were examined to determine the neutronic feasibility of the designs. The designs considered were (1) a 199-fuel-pin, 12-poison-reflector-control-drum reactor; (2) a 232-fuel-pin reactor with 12 reflector drums and three in-core control rods; (3) a 337-fuel-pin design with 12 incore control rods; and a 181-fuel-pin design with six drums closely coupled to the core to increase reactivity per drum. Adequate reactivity control and excess reactivity could be obtained for each concept, and the goals of 50,000 hours at 2.17 thermal megawatts with a lithium-7 coolant outlet temperature of 1222 K could be met without exceeding the 1-percent-clad-creep criterion. Heating rates in the boron carbide were calculated, but a heat transfer analysis was not done.

Mayo, W.↗

NASA NTRS1968

Glassy materials investigated for nuclear reactor applications

Studies determine the feasibility of preparing fuel-bearing glasses and glasses bearing neutron-absorbing materials for use as crystalline fuel and control rods for reactors. Properties investigated were devitrification resistance, urania solubility, and density.

Lynch, E. D.↗

NASA NTRS1987

Flutter study of an advanced composite wing with external stores

A flutter test using a scaled model of an advanced composite wing for a Navy attack aircraft has been conducted in the NASA Langley Research Center Transonic Dynamics Tunnel. The model was a wall-mounted half-span wing with a semi-span of 6.63 ft. The wing had an aspect ratio of 5.31, taper ratio of 0.312, and quarter-chord sweep of 25 degrees. The model was supported in a manner that simulated the load path in the carry-through structure of the aircraft and the symmetric boundary condition at the fuselage centerline. The model was capable of carrying external stores from three pylon locations on the wing. Flutter tests were conducted for the wing with and without external stores. No flutter was encountered for the clean wing at test conditions which simulated the scaled airplane operating envelope. Flutter boundaries were obtained for several external store configurations. The flutter boundaries for the fuel tanks were nearly Mach number independent (occurring at constant dynamic pressure). To study the aerodynamic effect of the fuel tank stores, pencil stores (slender cylindrical rods) which had the same mass and pitch and yaw inertia as the fuel tanks were tested on the model. These pencil store configurations exhibited a transonic dip in the flutter dynamic pressure, indicating that the aerodynamic effect of the actual fuel tanks on flutter was significant. Several flutter analyses methods were used in an attempt to predict the flutter phenomenon exhibited during the wind-tunnel test. The analysis gave satisfactory predictions of flutter for the pencil store configurations, but unsatisfactory correlation for the actual fuel tank configurations.

Cole, Stanley R.↗

NASA NTRS2017

Investigation of a Tricarbide Grooved Ring Fuel Element for a Nuclear Thermal Rocket

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nuclear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the temperature limitations of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment.

Taylor, Brian D.↗

NASA NTRS2018

Demonstration of Subscale Cermet Fuel Specimen Fabrication Approach Using Spark Plasma Sintering and Diffusion Bonding

Nuclear thermal propulsion (NTP) has the potential to expand the limits of human space exploration by enabling crewed missions to Mars and beyond. The viability of NTP hinges on the development of a robust nuclear fuel material that can perform in the harsh operating environment (> or = 2500K, reactive hydrogen) of a nuclear thermal rocket (NTR) engine. Efforts are ongoing to develop fuel material and to assemble fuel elements that will be stable during the service life of an NTR. Ceramic-metal (cermet) fuels are being actively pursued by NASA Marshall Space Flight Center (MSFC) due to their demonstrated high-temperature stability and hydrogen compatibility. Building on past cermet fuel development research, experiments were conducted to investigate a modern fabrication approach for cermet fuel elements. The experiments used consolidated tungsten (W)-60vol%zirconia (ZrO2) compacts that were formed via spark plasma sintering (SPS). The consolidated compacts were stacked and diffusion bonded to assess the integrity of the bond lines and internal cooling channel cladding. The assessment included hot hydrogen testing of the manufactured surrogate fuel and pure W for 45 minutes at 2500 K in the compact fuel element environmental test (CFEET) system. Performance of bonded W-ZrO2 rods was compared to bonded pure W rods to access bond line integrity and composite stability. Bonded surrogate fuels retained structural integrity throughout testing and incurred minimal mass loss.

Barnes, Marvin W.↗

NASA NTRS1974

Bibliography on aircraft fire hazards and safety. Volume 1: Hazards. Part 1: Key numbers 1 to 817

Ignition temperatures of n-hexane, n-octane, n-decane, JP-6 jet fuel, and aircraft engine oil MIL-7-7808 (0-60-18) were determined in air using heated Pyrex cylinders and Nichrome wires, rods, or tubes. Ignition temperature varied little with fuel-air ratio, but increased as the size of the heat source was decreased. Expressions are given which define the variation of the hot surface ignition temperatures of these combustibles with the radius and the surface area of the heat source. The expressions are applicable to stagnant or low velocity flow conditions (less than 0.2 in./sec.). In addition, the hot gas ignition temperatures of the combustible vapor-air mixtures were determined with jets of hot air. These ignition temperatures also varied little with fuel-air ratio and increased as the diameter of the heat sources was decreased.

Pelouch, J. J., Jr.↗

NASA NTRS2018

High-Fidelity Computational Methodology for Stitched Composite Aerospace Structures

Due to the high demands for energy efficient commercial transportation, the aviation industry has taken a leading role in the integration of composite structures. Among the leading concepts to develop lighter, more fuel-efficient commercial transport is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, an enabling technology for hybrid wing bodies. Many proof-of-concept tests have been performed to demonstrate that the use of PRSEUS has improved the residual strength of damaged structures compared to conventional composite structures, but efficient computational tools must be developed before the concept can be commercially certified and implemented. In an attempt to address the need for efficient computational tools, a comprehensive modeling approach is developed and applied to investigate applications of PRSEUS at multiple scales. Therefore, a computational methodology has been progressively developed based on physically realistic concepts. The focus of the work described herein is to define the modeling characteristics required to accurately simulate the damage progression and failure of PRSEUS at the coupon scale. The work herein is focused on the development and analysis of a PRSEUS stringer, the methodology for which may be extended to other PRSEUS coupons and components.

Brandon Horton↗

NASA NTRS2016

Correlation of Normal Gravity Mixed Convection Blowoff Limits with Microgravity Forced Flow Blowoff Limits

The axisymmetric rod geometry in upward axial stagnation flow provides a simple way to measure normal gravity blowoff limits to compare with microgravity Burning and Suppression of Solids - II (BASS-II) results recently obtained aboard the International Space Station. This testing utilized the same BASS-II concurrent rod geometry, but with the addition of normal gravity buoyant flow. Cast polymethylmethacrylate (PMMA) rods of diameters ranging from 0.635 cm to 3.81 cm were burned at oxygen concentrations ranging from 14 to 18% by volume. The forced flow velocity where blowoff occurred was determined for each rod size and oxygen concentration. These blowoff limits compare favorably with the BASS-II results when the buoyant stretch is included and the flow is corrected by considering the blockage factor of the fuel. From these results, the normal gravity blowoff boundary for this axisymmetric rod geometry is determined to be linear, with oxygen concentration directly proportional to flow speed. We describe a new normal gravity 'upward flame spread test' method which extrapolates the linear blowoff boundary to the zero stretch limit in order to resolve microgravity flammability limits-something current methods cannot do. This new test method can improve spacecraft fire safety for future exploration missions by providing a tractable way to obtain good estimates of material flammability in low gravity.

microgravity↗

NASA NTRS2017

Mixed Convection Blowoff Limits as a Function of Oxygen Concentration and Upward Forced Stretch Rate for Burning Pmma Rods of Various Sizes

Normal gravity flame blowoff limits in an axisymmetric pmma rod geometry in upward axial stagnation flow are compared with microgravity Burning and Suppression of Solids II (BASS-II) results recently obtained aboard the International Space Station. This testing utilized the same BASS-II concurrent rod geometry, but with the addition of normal gravity buoyant flow. Cast polymethylmethacrylate (pmma) rods of diameters ranging from 0.635 cm to 3.81 cm were burned at oxygen concentrations ranging from 14 to 18 by volume. The forced flow velocity where blowoff occurred was determined for each rod size and oxygen concentration. These blowoff limits compare favorably with the BASS-II results when the buoyant stretch is included and the flow is corrected by considering the blockage factor of the fuel. From these results, the normal gravity blowoff boundary for this axisymmetric rod geometry is determined to be linear, with oxygen concentration directly proportional to flow speed. We describe a new normal gravity upward flame spread test method which extrapolates the linear blowoff boundary to the zero stretch limit to resolve microgravity flammability limits, something current methods cannot do. This new test method can improve spacecraft fire safety for future exploration missions by providing a tractable way to obtain good estimates of material flammability in low gravity.

blowoff↗

NASA NTRS1958

Lightning Hazards to Aircraft Fuel Tanks

The hazards of lightning strokes to aircraft fuel tanks have been investigated in artificial-lightning-generation facilities specifically constructed to duplicate closely the natural lightning discharges to air craft determined through flight research programs and analysis of lightning-damaged aircraft over a period of many years. Explosion studies were made in an environmental explosion chamber using small fuel tanks under various simulated flight conditions. The results showed that there is a primary hazard whenever there is direct puncture of the fuel-tank wall, whereas the ignition of fuel by hot spots on tank walls due to lightning strikes is unlikely. Punctures of fuel-tank walls by artificial-lightning discharges produced explosions of the fuel in the mixture range from excessively lean to rich mixtures. None of the aluminum alloys, 0.081 inch thick or over, were punctured by the laboratory discharges representative of natural-lightning discharges to aircraft; however, reliance on this wall thickness for complete protection would not be justified, because occasional strokes are known to be of greater magnitude and because statistics reveal variations in the damage pattern. Data gathered by the Lightning and Transients Research Institute on lightning strokes to aircraft show that 90 percent of the strokes recorded have occurred in the temperature range of -10° to +10° C, where many of the jet fuels are flammable but where aviation gasoline is overrich. Also, 10 percent of the strokes recorded have been to the wings, which are the principal fuel-storage areas for modern aircraft. Thus, there is a hazard, particularly for jet fuels. Certain protective measures are indicated by the studies to date, such as the use of lightning diverter rods, thickening of the wing skin in areas near the most probable stroke paths, and the use of fuel-tank liners in critical areas.

Robb, J. D.↗

NASA NTRS2004

Finite Element Analysis of MEMS Devices

A side-slide actuator and a corrugated diaphragm actuator will be analyzed and optimized this summer. Coupled electrostatic and fluid analyses will also be initiated. Both the side-slide actuator and the corrugated diaphragm actuator will be used to regulate the flow of fuel in a jet engine. Many of the side-slide actuators will be placed on top of a fuel injector that is still in the developmental stage as well. The corrugated diaphragm actuator will also be used to regulate the flow of fuel in fuel injectors. A comparative analysis of the performance matrix of both actuators will be conducted. The side-slide actuator uses the concept of mechanical advantage to regulate the flow of fuel using electrostatic forces. It is made from Nickel, Silicon Carbide, and thin layers of Oxide. The slider will have a hole in the middle that will allow fuel to pass through the hole underneath it. The goal is to regulate the flow of fuel through the inlet. This means that the actuator needs to be designed so that when a voltage is applied to the push rod, the slider will deflect in the x-direction and be able to completely block the inlet and no fuel can pass through. Different voltage levels will be tested. The parameters that are being optimized are the thickness of the diaphragm, what kind of corrugation the diaphragm should have, the length, width, and thickness of the push rod, and what design should be used to return the slider. The current possibilities for a return rod are a built in spring on the slider, a return rod that acts like a spring, or a return rod that is identical to the push rod. The final actuator design should have a push rod that has rotational motion and no translation motion, a push rod thickness that prevents warping due to the slider, and a large ratio of the displacement on the bottom of the push rod to displacement on the top of the push rod. The corrugated diaphragm actuator was optimized last winter and this summer will be spent completing the optimization of the coupled electrostatic and fluid flow parameters. It was found that Nickel is the best material to use for the diaphragm because it has a higher yield strength and allows for a larger stress, deflection and applied pressure. The parameters that were optimized were the wavelength and thickness of the diaphragm.

Corrigan, Jennifer↗

NASA NTRS2011

Compressive Behavior of Frame-Stiffened Composite Panels

New technologies are being developed under NASA's Environmentally Responsible Aviation (ERA) Program aimed at reducing fuel burn and emissions in large commercial aircraft. A Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed which offers advantages over traditional metallic structure. In this concept a stitched carbon-epoxy material system is employed with the potential for reducing the weight and cost of transport aircraft structure by eliminating fasteners and producing a more damage tolerant design. In addition, by adding unidirectional carbon rods to the top of stiffeners and minimizing the interference between the sandwich frames and the rod-stiffened stringers, the panel becomes more structurally efficient. This document describes the results of experimentation on a PRSEUS panel in which the frames are loaded in unidirectional compression beyond the local buckling of the skin of a Hybrid Wing Body (HWB) aircraft. A comparison with analytical predictions and the relationship between these test results and the global aircraft design is presented.

Yovanof, Nicolette P.↗

NASA NTRS1991

Wire core reactor for NTP

The development of the wire core system for Nuclear Thermal Propulsion (NTP) that took place from 1963 to 1965 is discussed. A wire core consists of a fuel wire with spacer wires. It's an annular flow core having a central control rod. There are actually four of these, with beryllium solid reflectors on both ends and all the way around. Much of the information on the concept is given in viewgraph form. Viewgraphs are presented on design details of the wire core, the engine design, engine weight vs. thrust, a technique used to fabricate the wire fuel element, and axial temperature distribution.

Harty, R. B.↗