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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Dimorphos’s Material Properties and Estimates of Crater Size from the DART Impact

On 2022 September 26, the Double Asteroid Redirection Test (DART) spacecraft intentionally collided with Dimorphos, the moon of the binary asteroid system 65803 Didymos. This collision provided the first full-scale test of a kinetic impactor for planetary defense. Images from DART’s DRACO camera revealed Dimorphos to be an oblate spheroid covered in boulders of varying sizes and shapes. Very little was known about Dimorphos prior to DART’s impact, including its shape, structure, and material properties. Approach observations and those following the DART impact have provided crucial knowledge that narrows the parameter space relevant to modeling the impact into Dimorphos. Here we present the results of a suite of hydrocode simulations of the DART impact on Dimorphos. Despite remaining uncertainties, initial models of DART’s kinetic impact provide important information about the results of DART (e.g., potential crater size and morphology, ejecta mass) and the properties of Dimorphos. Simulations here suggest that Dimorphos has near-surface strength ranging from a few Pascals to tens of kPa, which corresponds to crater sizes of ~40–60 m. Simulated crater sizes provide a crucial comparison metric for the European Space Agency Hera mission when it arrives at the Didymos system. Hera’s measurement of crater size in combination with measurement of Dimorphos’s mass will allow us to assess our simulations and provide the information needed to make the DART impact experiment both the first test of a planetary defense mitigation mission and the first full-scale planetary defense simulation validation exercise.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design and Study of Inductively Coupled Plasma Chamber Components Using the SupRISE Test Device at DIII-D

The DIII-D National Fusion Facility aims to increase the auxiliary heating power for the tokamak by upgrading the Neutral Beam Injection (NBI) system. In collaboration with North Carolina State University, the conventional ‘arc and filament’ NBI ion sources will be converted to inductively coupled plasma (ICP) sources which utilize radio frequency (RF) coupling to maximize reliability for high power operation. In support of this initiative, a full scale test device (SupRISE, Superior Radiofrequency Ion Source Experiment) is currently under construction at the DIII-D Facility. In preparation for the construction of a full scale prototype that can be installed on the DIII-D NBI system, experiments on SupRISE will be conducted to determine the optimal RF frequency for high power coupling, Faraday shield slit configuration, and ICP chamber length. SupRISE is comprised of an approximately 30 x 70 cm quartz dielectric vessel with an internal Faraday shield enclosed in a secondary vacuum chamber to ensure structural stability of the dielectric. Actively cooled front and back plates are designed to reduce the thermal stresses on the plasma facing components and mate with the existing accelerator used by the NBI system at DIII-D. 50 kW of RF power will be coupled to the plasma through the quartz over a variable frequency range of 4-8 MHz to sustain a plasma density of ∼ 10 18 m −3 for a 10 s ON, 210 s OFF duty cycle. Various modelling efforts have been employed to simulate the thermal and stress profiles over the primary components of the SupRISE device as well as the inductance behavior of the RF antenna. These simulation results and the final design for SupRISE will be presented. An additional reduced-scale predecessor ICP source (called RISE) has been used to develop a predictive match model that will be applied to frequency optimization studies on SupRISE. Furthermore, the outcomes of this research and complementary efforts at North Carolina State University are essential for the incorporation of ICP NBI positive ion sources at the DIII-D facility.

DIII-D↗
DOE OSTI2023

A Fast Reactor Irradiation Experiment Design in the ATR

Modern modeling techniques were used to investigate a proposed method for fast neutron irradiations in an existing thermal-spectrum reactor, the Advanced Test Reactor (ATR). This method builds upon pre-existing ideas, where fast flux is increased by surrounding the specimens with fissionable “booster fuel” but diverges from historical approaches by using an already developed fuel element design used in the Belgian Reactor 2 (BR2) as the booster fuel while leveraging modern 3-D modeling and simulation techniques. Design evaluations and neutronics simulations were performed to evaluate the performance of a BR2 fuel element irradiated in an ATR flux trap with test pins in the central channel of the BR2 fuel element. These efforts have yielded promising results. Adding a BR2 fuel element in the northeast (NE) flux trap of ATR was predicted to result in a 150% increase to the incident fast neutron flux with a fast (>0.1 MeV) to thermal (<0.625 eV) neutron flux ratio ranging from approximately 50 to 150, dependent on the material used for thermal neutron filtering and volume of moderator within the central channel of the BR2 element. The predicted annual fast neutron fluence (>0.1 MeV) ranges from 7.9 × 1021 to 9.1 × 1021 n/cm2. Given the relatively large fast to thermal neutron flux ratio, the calculated radial power profiles within 4.3 mm outer diameter U10Zr fueled specimens irradiated within the BR2 booster fuel element are adequate representations of those within fast neutron reactors. The predicted radial power profiles are not flat, but they are more prototypic than those seen in advanced fuels tests which began in ATR in 2003. Another distinct advantage of this experiment design is that full-scale test pins can be irradiated to augment the ongoing series of reduced scale advanced fuels tests. The proposed experiment design irradiated within a BR2 fuel element in a flux trap of ATR offers an improved alternative to the current testing of advanced reactor fuels in ATR. Selected results from this design evaluation are presented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Terry Turbopump Expanded Operating Band Modeling and Simulation Efforts in Fiscal Year 2020 - Progress Report

The Terry Turbine Expanded Operating Band Project is currently conducting testing at Texas A&M University as part of a revised experimental program meant to supplant previous full-scale testing plans under the headings of Milestone 5 and Milestone 6. In consultation with Sandia National Laboratories technical staff and with modeling and simulation support from the same, the hybrid Milestone 5&6 plan is moving forward with experiments aimed at addressing knowledge gaps regarding scale, working fluid, and turbopump self-regulation. Modeling and simulation efforts at Sandia National Laboratories in FY20 fell under the broad umbrella of Milestone 7 and consisted exclusively of MELCOR-related tasks aimed at: 1) Constructing/improving input models of Texas A&M University experiments, 2) Constructing a generic boiling water reactor input model according to best practices with systems-level Teny turbine capabilities, and 3) Adding code capability in order to leverage experimental data/findings, address bugs, and improve general code robustness Project impacts of the Covid-19 pandemic have fortunately been minimal thus far but are mentioned as necessary when discussing the hybrid Milestone 5&6 progress as well as the corresponding Milestone 7 modeling and simulation progress.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Flow Sensor Test Article (F-STAr) (Design and Fabrication Status Report)

The Flow Sensor Test Article (F-STAr) is a test article currently under construction for the Mechanisms Engineering Test Loop (METL). F-STAr was designed to provide high sodium flowrate capabilities for sensor calibration, component testing, and fluid studies. Figure 1 shows two solid model views of the new test article. F-STAr includes a high-capacity pump that can provide a nominal flowrate of 120 GPM; a test section support structure that can accommodate a wide array of sub-test articles and their instrumentation; and finally, a heating and cooling system to aid in controlling the testing environment. Initially, F-STAr will be configured to test liquid metal flow sensors, specifically field shift sensors like the Eddy Current Flow Sensors (ECFS) based on the RDT C4-7T standard. To test these sensors, two test sections were designed that attempt to model Sodium Fast Reactor (SFR) outlet conditions. Figure 2 shows models of the “Full-Scaled Test Section” (FSTS) that represents a generic SFR fuel handling socket and a “Pseudo-Scaled Test Section” (PSTS) that represents a generic array of scaled fuel handling sockets. While F-STAr will be configured to test ECFS’s, it can also be outfitted to meet other experimental needs. For example, F-STAr could be setup with a test section that includes a fluidic diode or a component test investigating the performance of hydrodynamic bearings. Other test sections include studies of sodium thermal hydraulics like thermal striping. Overall, F-STAr is a flexible test article designed to accommodate many needs. This report will provide a status update on the design and construction of F-STAr. Manufacturing of all components has commenced, and several components have already been completed. These components include the pump and test section assembly stand. Other components, such as the heater, have been completed but were rejected due to the vendor not meeting the requirements of the purchase order. Lastly, the submersible flowmeter and main flange components are under construction, and their status will be reviewed in this report. Overall, most of the F-STAr components and parts will be completed by the end of September 2022.

42 ENGINEERING↗
DOE OSTI2025

A comparative analysis of numerical approaches for the description of gas flow in clay-based repository systems: From a laboratory to a large-scale gas injection test

There is nowadays a consensus among many countries that geological disposal is a favourable solution for the long-term management. Although different host formations and different barrier systems are under consideration around the world, clay-based materials form an important component for waste isolation in most national programmes. Hence, a good comprehension of the effect of gas flow on the hydro-mechanical behaviour of clay-based soils is essential, both at laboratory and field scale. Task B under the international cooperative project DECOVALEX-2023 has recently shown that, after some enhancement, models can be employed to reproduce laboratory scale tests, even with different sample geometries 37 . However, further work is required to understand whether they can be applied to simulate a large-scale experiment. Up-scaling of models for the advective transport of gas through clay-based low permeable material presents a number of problems related to the difficulty in obtaining consistent hydrogeological parameters and constitutive relationships at both laboratory and field scale. Based on a unique dataset from a large-scale gas injection test (Lasgit) performed at the Äspö Hard Rock Laboratory (Sweden), Task B within DECOVALEX-2023 has explored the refinement of these numerical strategies applied to the simulation of gas flow. Work performed within the task reveals that codes do not need to be substantially modified from the laboratory models to reproduce full-scale tests: indeed, model parameters calibrated and validated at laboratory scale have been applied to predict field scale gas flow at Lasgit, including peak gas pressure and injected cumulative gas volume. By means of (1) the introduction of interfaces between blocks to reflect the experimental configuration and the (2) adjustment of some parameters (e.g., higher permeability), the updated models are able to represent most of the key features observed in the experimental data, even at a large scale.

Tamayo-Mas, E↗
DOE OSTI2020

Oil miscible phosphonium-phosphate ionic liquid as novel antiwear and antipitting additive for low-viscosity rear axle lubricants

Here we explored the feasibility of using a phosphonium phosphate ionic liquid as a candidate anti-wear and anti-pitting additive for rear axle lubricant. This particular IL was first added to a VHVI8 base oil at 2–3% concentration and demonstrated effective surface protection for wear and micro-cracking under rolling-sliding contacts. The promising results directed to a step further to produce a series of IL-containing low-viscosity (about a half of SAE 75W-90) fully formulated gear oils. Selected IL-containing experimental oils showed superior mitigation of rolling contact fatigue to a commercial SAE 75W-90 gear oil in bench-scale rolling-sliding tests. Full-scale hub dynamometer tests were then conducted and demonstrated more than 3% power output and torque generation for an IL-containing low-viscosity gear oil benchmarked against commercial baselines.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Trinity 78th Anniversary: re-discovered and newly edited unclassified footage shows use of tanks to collect radioactive samples immediately after Trinity test (Rev. 1)

On July 16, 1945, at 5:29 a.m., a team of Los Alamos scientists successfully detonated the world’s first atomic bomb at a remote section of south-central New Mexico desert, then known as the Alamogordo Bombing Range. This full-scale test, dubbed “Trinity” by the Lab’s first Director J. Robert Oppenheimer, proved the viability of the implosion-type bomb known as The Gadget and ushered in the Atomic Age. Three weeks after Trinity, two Los-Alamos created atomic weapons – Little Boy and Fat Man – were released above Japan, helping to end World War II and changing the course of history forever.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2021

Hanford Waste Treatment Plant LAB Facility Stack Effluent Monitoring: Sampling Probe Location Qualification Evaluation

The WTP LAB stack monitor locations were qualified using scale model stacks to mitigate the risk of identifying that sampling locations do not meet the qualification criteria on the full-scale stack. As required by the ANSI/HPS N13.1-1999 standard, the scale model and its sampling location were geometrically similar to the actual stack and the Reynolds numbers for both the actual and model stacks were >10,000. An additional criterion is that the DV of the full-scale stack must be between 1/6 DV and 6 DV of the scale model stack tests. Verification tests of the LAB stacks were performed at normal operating conditions. The maximum 6 DV value from the scale model testing determines the maximum conditions for which the full-scale stack may be operated and remain in compliance with the stack verification criterion. The remaining criteria for the stack verification to be considered valid involve the flow angle and velocity uniformity results. First, the flow angle at the full-scale stack must be = 20°. Second, the velocity uniformity at the full-scale stack must be = 20% COV. Finally, the velocity uniformity results for the actual and scale model stacks must agree within 5% COV. In general, these criteria were met through the full-scale stack tests at the LAB facility. Some specific items for each scale model and full-scale stack comparison should be noted in assessing the validity of the verification tests. The LB-C2 scale model stacks were performed with single fan operations at then-minimum flow conditions. These conditions resulted in DV values that were too low to meet the DV range criterion, and therefore are unable to be used in qualifying single fan operations on the full-scale stack. However, the single fan operations demonstrated COV values for velocity uniformity as well as flow angles that were comparable to the dual-fan operations at high flows. Overall, the test conditions and test results were within the range of acceptable values based on current design flow rates. Single fan operations are expected to only occur infrequently for maintenance needs and is therefore not a planned operating condition at this time. The LB-S1 scale model stacks were performed at three fan combinations, and in each combination, at least one test was performed at the then-minimum flow conditions as well as at then-maximum flow conditions. While the then-minimum flow conditions result in a DV range that is lower than the verification test DV value, and therefore does not meet the criterion, these tests are un-necessary for the verification test acceptance. The normal and maximum flow conditions from the scale model stack tests meet the DV range criterion, and the velocity uniformity test results compare favorably with the full-scale stack results. The LB-S2 scale model stacks were performed at nominally the same maximum flow condition; however, the 6 DV value for Fan A operation was slightly lower than the full-scale stack test DV. The COV values from the scale model stacks were comparable between the Fan A and Fan B results, and the overall test conditions are within the range of acceptable values. The stack verification is therefore considered acceptable for both Fan A and Fan B operations. The verification tests were performed at flows that were appreciably higher than the design conditions, and further elevated flow rates would be beyond the range of acceptable DV. Based on these stack verification test results, the three LAB filtered exhaust stacks meet the qualification criteria provided in the ANSI/HPS N13.1-1999 standard. Further changes to the system configuration or operating conditions that are outside the bounds described in this and the scale model test reports (Glissmeyer, Flaherty, and Piepel (2001), Glissmeyer and Geeting (2013)) may require additional tests and additional analyses to determine compliance with the standard.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Experimental validation of a co-simulation architecture for modeling whole-building and detailed electrical distribution performance

This article presents an experimental validation of a co-simulation architecture for simultaneously modeling whole-building energy performance and detailed building electrical distribution system performance. The co-simulation architecture consists of a whole-building energy model (EnergyPlus®) embedded within a Modelica-based building electrical distribution system library called the Building Electrical Efficiency Analysis Model (BEEAM) using the Functional Mock-up Interface standard. We validate the model using experimental data collected at a full-scale test cell within Lawrence Berkeley National Laboratory’s FLEXLAB® facility. In conclusion, we show that the co-simulation model accurately predicts the electrical, mechanical, and thermal performance of the test cell for typical loads with both an AC and a DC electrical distribution topology.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

A Modular Mechanism for Downhole Weight-on-Bit and Torque Reaction in Small Diameter Boreholes

Drilling systems that use downhole rotation must react torque either through the drill-string or near the motor to achieve effective drilling performance. Problems with drill-string loading such as buckling, friction, and twist become more severe as hole diameter decreases. Therefore, for small holes, reacting torque downhole without interfering with the application of weight-on-bit, is preferred. In this paper, we present a novel mechanism that enables effective and controllable downhole weight on bit transmission and torque reaction. This scalable design achieves its unique performance through four key features: (1) mechanical advantage based on geometry, (2) direction dependent behavior using rolling and sliding contact, (3) modular scalability by combining modules in series, and (4) torque reaction and weight on bit that are proportional to applied axial force. As a result, simple mechanical devices can be used to react large torques while allowing controlled force to be transmitted to the drill bit. We outline our design, provide theoretical predictions of performance, and validate the results using full-scale testing. The experimental results include laboratory studies as well as limited field testing using a percussive hammer. These results demonstrate effective torque reaction, axial force transmission, favorable scaling with multiple modules, and predictable performance that is proportional to applied force.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Concentric Ring Gas Atomization Die Design for Optimized Particle Production

In partnership with Linde plc (formerly Praxair, Inc.), Ames Laboratory will further develop and commercialize its concentric-ring high pressure gas atomization (CR-HPGA) gas-die technology with a goal to improve the precision of metal powder production in a desired size range and quality. The successful commercialization of this technology could reduce production cost of metal powders and improve reliability of this industrial process, increasing specialty alloy powder availability for new applications and adoption into additive manufacturing and multiple materials sectors. The project scope is to [1] utilize AMES compressible gas flow and melt break-up models to explore a wide swath of parameter space available for the CR-HPGA technology, identifying the most promising gas-die designs for fabrication, [2] verify and optimize the new gas-die design, fabricate it and select preferred operating parameters by gas-only flow imaging and aspiration pressure measurements, down-selecting gas compositions and atomization parameters for full scale testing, [3] perform pilot-scale atomization trials with Al and/or Cu alloys of a new CR-HPGA gas-die at selected parameters, [4] evaluate gas-die performance by comparing resulting powder size distribution and powder quality attributes with equivalent powders made by conventional close-coupled HPGA technology, and [5] assess (through Praxair partnership) reduction in operational costs of new CR-HPGA gas-die through the use of an inert gas recovery/recycling system. In partnership with Praxair, Inc., the team, led by Ames Laboratory senior metallurgist Iver Anderson, intend to demonstrate the performance of an optimized CR-HPGA gas-die design in a pilot scale atomizer and better understand the design and operational controls to increase overall benefits for precision metal powder production.

42 ENGINEERING↗
DOE OSTI2021

Aluminization Coatings and Glass Seals for High Temperature System: CRADA 536 [Abstract Only]

The proposed work will demonstrate the suitability of PNNL Reactive Air Aluminization (RAA) coatings (US Patent Numbers 10,577,694, 10,378,094, and 9,481,923) for use in high-temperature systems. In particular, the Participant and Contractor will explore applicability of these coatings in Participant’s high-temperature hydrogen reactors where they would be used to prepare the sealing surfaces of the reactor technology. Utility Global will also instruct PNNL regarding their needs relating to the further development of glass seal technologies that are suitable for use in their systems. This effort will entail alkaline earth-based silicate glass development and characterization; evaluation and characterization of reliability and compatibility of the coatings with glass seals, working environments, and substrates; performance demonstrations of representative cells and intermediate cells sealed using the glass seals and/or coatings of interest; and incorporation of the aluminization coatings and glass seals into the reactor for full-scale testing.

08 HYDROGEN↗
DOE OSTI2024

Summary of Gas Generation Behavior Observed in 3013 Surveillance and Monitoring Program Shelf-Life Experiments

Gas generation experiments have been conducted in small- and full-scale test containers at Los Alamos National Laboratory on samples of plutonium oxide material collected from plutonium processes across the DOE complex and tested at the bounding conditions for the Department of Energy 3013 Standard. The gas composition and pressures in the sealed experimental containers were measured over periods of months to years. These experiments have provided results for the formation and consumption of hydrogen and other gases. The conditions supporting the formation of flammable gas mixtures of hydrogen and oxygen in flammable gas mixtures were also determined. Different behaviors were observed between the materials tested based on their compositions, the stabilization performed on the material, and the post stabilization handling of the material. Many of the experiments are still ongoing. This report summarizes the results obtained for the gas generation behavior for high-purity plutonium oxides and salt-bearing impure plutonium oxides in sealed containers.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Super Conducting REBCO Cable Wrapper

Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.

Gillen, Kameron [Northern Illinois U.]↗
DOE OSTI2024

Full-Scale Development and Piloting of a Hybrid Digital Twin for Wastewater Operations Optimization

This full-scale pilot of a machine learning based nutrient controller/digital twin is being done as part of The Water Research Foundation (WRF) project 5121: Development of Innovative Predictive Control Strategies for Nutrient Removal. The overall goal of this project is to develop and full-scale test a hybrid (machine learning + mechanistic model) nutrient management controller at four different water resource recovery facilities (WRRFs). The controller demonstrates both short-term optimization functions and predictive capabilities. This project includes the design of the controller, its performance at the WRRFs, and a description of the future improvements.

Johnson, Bruce↗
DOE OSTI2025

Status of the Down-Blending of Irradiated IGR Graphite Fuel in Kazakhstan

Dry processing remains the primary solution for managing the down-blending of irradiated IGR HEU fuel. Several tasks have been initiated and completed to achieve this, including lab modernization, lab-scale and full-scale testing, designing and fabricating an in-paddle mixing drum, and commissioning both a down-blending system and a crushing and milling system. Additionally, a testing and training center was modernized, the equipment was successfully commissioned, and the IGR HEU fuel blocks were repackaged into daily containers. The training of operators and the construction of a new down-blending facility are tasks that will need to be completed in the near future. The progress in these areas continues to validate that the proposed method for down-blending irradiated HEU graphite fuel, followed by cementation of the down-blended material for permanent disposition, appears to be achievable.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗
DOE OSTI2022

Full-Scale Hydrogen Mitigation Installation and Testing at Nevada Solar One

This project was performed under a Cooperative Research & Development Agreement (CRADA) between the National Renewable Energy Laboratory (NREL) and Acciona Energy USA (AE). The purpose was to advance an NREL TRL 3 technology that was developed during the previous CRADA from completed laboratory testing to full-scale process installation and testing at AE's Nevada Solar One (NSO) power plant. The project's objective was to complete full-scale implementation and performance verification of the NREL hydrogen mitigation technology at the Nevada Solar One (NSO) power plant in Boulder City, Nevada.

08 HYDROGEN↗