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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

Thermal Vacuum Testing of a Helium Loop Heat Pipe for Large Area Cryocooling

Future NASA space telescopes and exploration missions require cryocooling of large areas such as optics, detector arrays, and cryogenic propellant tanks. One device that can potentially be used to provide closed-loop cryocooling is the cryogenic loop heat pipe (CLHP). A CLHP has many advantages over other devices in terms of reduced mass, reduced vibration, high reliability, and long life. A helium CLHP has been tested extensively in a thermal vacuum chamber using a cryocooler as the heat sink to characterize its transient and steady performance and to verify its ability to cool large areas or components in the 3 degrees Kelvin temperature range. The helium CLHP thermal performance test included cool-down from the ambient temperature, startup, capillary limit, heat removal capability, rapid power changes, and long duration steady state operation. The helium CLHP demonstrated robust operation under steady state and transient conditions. The loop could be cooled from the ambient temperature to subcritical temperatures very effectively, and could start successfully by simply applying power to both the capillary pump and the evaporator plate without pre-conditioning. It could adapt to a rapid heat load change and quickly reach a new steady state. Heat removal between 10 megawatts and 140 megawatts was demonstrated, yielding a power turn down ratio of 14. When the CLHP capillary limit was exceeded, the loop could resume its normal function by reducing the power to the capillary pump. Steady state operations up to 17 hours at several heat loads were demonstrated. The ability of the helium CLHP to cool large areas was therefore successfully verified.

Thermal Control Systems↗

INL POSTER 2025- KRYSTAL FOSTER

The Advanced Test Reactor (ATR) employs the N-16 system to measure reactor power by detecting beta particles emitted from nitrogen-16 isotopes. During startup, the N-16 pumps cause rapid oscillations in the discharge piping due to pressure transients, which cease when the valve supplying N-16 flow to the reactor is opened. To address this, a soft-starter is proposed to gradually increase the motor voltage, reducing mechanical stress and preventing pressure surges. This solution enhances system stability, lowers maintenance costs, extends equipment lifespan, and is more cost-effective than Variable Frequency Drives (VFDs), making it ideal for the infrequently activated N-16 pumps.

42 - ENGINEERING↗

An integrated statistical-thermodynamic model for fission gas release and swelling in nuclear fuels

Here, we propose a new model for burst fission gas release induced by microcracking in ceramic nuclear fuels such as uranium dioxide. The model stipulates that the densities of defects in the fuel material, such as microcracks and fission gas bubbles on grain boundaries, evolve in accordance with the second law of thermodynamics. Central to the model is the notion of an effective temperature, conjugate to the configurational entropy of the fuel material, and directly linked to the burnup. The model predicts that microcracking, driven by the internal stress state of the fuel material, reduces the bubble storage capacity of grain boundaries, and accounts for burst fission gas release during rapid temperature transients that simulate power transients, reactor startup, and loss-of-coolant accident conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Lifetime Reliability Prediction of Ceramic Structures Under Transient Thermomechanical Loads

An analytical methodology is developed to predict the probability of survival (reliability) of ceramic components subjected to harsh thermomechanical loads that can vary with time (transient reliability analysis). This capability enables more accurate prediction of ceramic component integrity against fracture in situations such as turbine startup and shutdown, operational vibrations, atmospheric reentry, or other rapid heating or cooling situations (thermal shock). The transient reliability analysis methodology developed herein incorporates the following features: fast-fracture transient analysis (reliability analysis without slow crack growth, SCG); transient analysis with SCG (reliability analysis with time-dependent damage due to SCG); a computationally efficient algorithm to compute the reliability for components subjected to repeated transient loading (block loading); cyclic fatigue modeling using a combined SCG and Walker fatigue law; proof testing for transient loads; and Weibull and fatigue parameters that are allowed to vary with temperature or time. Component-to-component variation in strength (stochastic strength response) is accounted for with the Weibull distribution, and either the principle of independent action or the Batdorf theory is used to predict the effect of multiaxial stresses on reliability. The reliability analysis can be performed either as a function of the component surface (for surface-distributed flaws) or component volume (for volume-distributed flaws). The transient reliability analysis capability has been added to the NASA CARES/ Life (Ceramic Analysis and Reliability Evaluation of Structures/Life) code. CARES/Life was also updated to interface with commercially available finite element analysis software, such as ANSYS, when used to model the effects of transient load histories. Examples are provided to demonstrate the features of the methodology as implemented in the CARES/Life program.

Nemeth, Noel N.↗

WEST full tungsten operation with an ITER grade divertor

The mission of WEST (tungsten-W Environment in Steady-state Tokamak) is to explore long pulse operation in a full tungsten (W) environment for preparing next-step fusion devices (ITER and DEMO) with a focus on testing the ITER actively cooled W divertor in tokamak conditions. Following the successful completion of phase 1 (2016-2021), phase 2 started in December 2022 with the lower divertor made entirely of actively cooled ITER-grade tungsten mono-blocks. A boronization prior the first plasma attempt allowed for a smooth startup with the new divertor. Despite the reduced operating window due to tungsten, rapid progress has been made in long pulse operation, resulting in discharges with a pulse length of 100 s and an injected energy of around 300 MJ per discharge. Plasma startup studies were carried out with equatorial boron nitride limiters to compare them with tungsten limiters, while Ion Cyclotron Resonance Heating assisted startup was attempted. High fluence operation in attached regime, which was the main thrust of the first campaigns, already showed the progressive build up of deposits and appearance of dust, impacting the plasma operation as the plasma fluence increased. In total, the cumulated injected energy during the first campaigns reached 43 GJ and the cumulated plasma time exceeded 5 h. Demonstration of controlled X-Point Radiator regime is also reported, opening a promising route for investigating plasma exhaust and plasma-wall interaction issues in more detached regime. This paper summarises the lessons learned from the manufacturing and the first operation of the ITER-grade divertor, describing the progress achieved in optimising operation in a full W environment with a focus on long pulse operation and plasma wall interaction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

CRADA Number NFE-18-07342 with Lux Semiconductors, LLC (CRADA Final Report)

Lux Semiconductors is a flexible microelectronics startup developing a new class of Systemon-Foil electronics for rapidly emerging Internet-of-Things (IoT) markets. By leveraging its patent pending breakthrough in thin-film recrystallization, Lux is able to produce highly crystalline and flexible silicon substrates on a thin metal backing. This novel platform allows for high-speed silicon circuitry to be patterned directly into the substrate alongside low-cost printed electronics. The System-on-Foil approach has potential to enable the fabrication and integration of all core IoT functionality, including microprocessors, sensors, antennas, interconnects, and power supplies, required to enable highly durable, low profile, flexible electronics.

42 ENGINEERING↗

Role of Inverter-Based Resources (IBRs) in Energizing Remote Generating Stations

The increasing integration of Inverter-Based Resources (IBRs) into the system has brought significant focus on their role in blackstart and restoration procedures. Their advantageous features, such as low startup power requirements, operational flexibility across a wide range of power factors, rapid controllability, and the ability to energize a network at lower voltage levels necessitate a reassessment of existing restoration protocols. This paper seeks to showcase how IBRs can utilize their grid-forming capabilities to provide power to a remote generating station through detailed EMT simulation studies using data collected from an existing portion of a network.

blackstart procedure↗

Integrity testing of brush seal in shroud ring of T-700 engine

A split-ring brush seal was fabricated, installed between two labyrinth-honeycomb shroud seals, and tested in the fourth-stage turbine of a T-700 engine. The annealed Haynes 25 bristles rubbed directly against the nonconditioned, irregular Rene 80 turbine blade shroud surface. A total of 30 hr of cyclic and steady-state data were taken with surface speeds to 335 m/s (1100 ft/s) and shroud temperatures to 620 C (1150 F). Wear appeared to be rapid initially, with an orange flash of hot brush fragments during the first engine startup, to minimal after 10 hr of operation. The brush survived the testing but experienced some bristle pullouts and severe bristle wear; some turbine interface wear and possible material transfer was noted. Future design concerns center on tribological behavior at the interface with or without lubricants.

Hendricks, Robert C.↗

Integrity testing of brush seal in a T-700 engine

A split-ring brush seal was fabricated, installed between two labyrinth-honeycomb shroud seals, and tested in the fourth-stage turbine of a T-700 engine. The annealed Haynes 25 bristles rubbed directly against the nonconditioned, irregular Rene 80 turbine blade shroud surface. A total of 21 hr of cyclic and steady-state data were taken with surface speeds of 335 m/s (1100 ft/s) and shroud temperatures to 620 C (1150 F). Wear appeared to be rapid initially, with an orange flash of hot brush fragments during the first engine startup, to minimal after 10 hr of operation. The brush survived the testing but experienced some bristle pullouts and severe bristle wear; some turbine interface wear and possible material transfer was noted. Future design concerns center on tribological behavior at the interface with or without lubricants.

Hendricks, Robert C.↗

Integrated Intelligent training and job aiding for combustion turbine engines

This paper describes an ongoing program to augment such an expert system gas turbine startup advisor, known as the EPRI SA VANT System, by including an intelligent training package. It will give a brief background on the SA VANT development and an overview of its evolution into a full-blown Gas Turbine Information System (GTIS) for rapid access of on-line documentation, diagnostics, and training. In particular, the paper will address: (1) the conversion of the knowledge base used by the SA VANT startup advisor so that it can be used for both training and job aiding; and (2) the hypertext-oriented user manuals being incorporated into the system for rapidly accessing on-line documentation at the job site.

Mckeithan, Clifford M., Jr.↗

Technology Transfer Excellence Award NTXBio

While a scientist at Los Alamos National Laboratory, Dr. Alex Koglin developed two compounds to create a better vaccine for Tuberculosis (TB). In 2015, Dr. Koglin took an entrepreneurial leave of absence from the Laboratory to start NTXBio, LLC. His objective was to develop and commercialize a TB vaccine based on two compounds he created while a scientist at the Los Alamos. In 2018, a total of 1.5 million people died from TB. According to the World Health Organization TB is the leading infectious disease resulting in death worldwide. Approximately one-quarter of the world’s population is infected with mycobacterium tuberculosis, the bacteria that causes TB. Dr. Koglin non-exclusively licensed the two compounds from Los Alamos and began further development of the technology in collaboration with the Government of South Africa and universities to address the need for a vaccine to prevent TB. In their research and development of the compounds there was no evidence of cross resistance between other bacteria and the bacteria that causes TB. The compounds were tested in mouse models and demonstrated they can treat TB. Also, the tests have not shown any of the massive side effects that the current treatments for TB are showing. The company started production of the compounds using current manufacturing processes. Using these processes NTXBio could not produce the compounds at a reasonable price to be available for patients in third world countries. The company shifted to developing a new methodology “invitro synthetic biology” that can increase the production of these compounds and other vaccine molecules in a more affordable way. Dr. Koglin’s startup NTXBio is working to positively influence and secure the world vaccine supply by developing rapid on-demand production of the full spectrum of protein vaccines. Starting with the TB vaccine and advancing to common childhood vaccines, emergency and experimental vaccines such as those needed for COVID-19. NTXBio is capable of accelerated prototyping and manufacturing with increased purity and greater stability while reducing both cost and production time. The newly developed production methodology can be applied to not only the TB compounds licensed from Los Alamos, but also to their compounds that advance vaccine production for other diseases. Their technology produces vaccines fast enough to be fully deployable in areas without the need of specialized storage conditions and response times.

60 APPLIED LIFE SCIENCES↗

Overload protection for switching regulators

Circuit protects all output lines of switching regulator against overloads without requiring current sensors on every line. If overload is sensed, device short circuits bias on switching transistor so that power is rapidly cut off from loads. Circuit also includes delay network to inhibit erroneous operation during startup.

Lachochi, E.↗

Lessons Learned on Prize Design in the Perovskite Startup Prize

In 2018, the U.S. Department of Energy's Solar Energy Technologies Office and the National Renewable Energy Laboratory set out to develop a repeatable, predictable prize model with the American-Made Challenges. A new model launched by the Solar Energy Technologies Office in March 2021 was the American-Made Perovskite Startup Prize. This new prize aimed to accelerate the growth of the domestic perovskite industry and support the rapid development of solar cells and modules that use perovskite materials. By sharing the outputs of the prize, we hope that our lessons learned will help continue to build the clean tech entrepreneurship support ecosystem and influence how a successful prize design can be achieved.

14 SOLAR ENERGY↗

Transient Three-Dimensional Side Load Analysis of a Film Cooled Nozzle

Transient three-dimensional numerical investigations on the side load physics for an engine encompassing a film cooled nozzle extension and a regeneratively cooled thrust chamber, were performed. The objectives of this study are to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Ultimately, the computational results will be provided to the nozzle designers for estimating of effect of the peak side load on the nozzle structure. Computations simulating engine startup at ambient pressures corresponding to sea level and three high altitudes were performed. In addition, computations for both engine startup and shutdown transients were also performed for a stub nozzle, operating at sea level. For engine with the full nozzle extension, computational result shows starting up at sea level, the peak side load occurs when the lambda shock steps into the turbine exhaust flow, while the side load caused by the transition from free-shock separation to restricted-shock separation comes at second; and the side loads decreasing rapidly and progressively as the ambient pressure decreases. For the stub nozzle operating at sea level, the computed side loads during both startup and shutdown becomes very small due to the much reduced flow area.

Wang, Ten-See↗

Flash evaporator systems test

A flash evaporator heat rejection system representative of that proposed for the space shuttle orbiter underwent extensive system testing at the NASA Johnson Space Center (JSC) to determine its operational suitability and to establish system performance/operational characteristics for use in the shuttle system. During the tests the evaporator system demonstrated its suitability to meet the shuttle requirements by: (1) efficient operation with 90 to 95% water evaporation efficiency, (2) control of outlet temperature to 40 + or - 2 F for partial heat load operation, (3) stability of control system for rapid changes in Freon inlet temperature, and (4) repeated dormant-to-active device operation without any startup procedures.

Dietz, J. B.↗

Vibration-Based Method Developed to Detect Cracks in Rotors During Acceleration Through Resonance

In recent years, there has been an increasing interest in developing rotating machinery shaft crack-detection methodologies and online techniques. Shaft crack problems present a significant safety and loss hazard in nearly every application of modern turbomachinery. In many cases, the rotors of modern machines are rapidly accelerated from rest to operating speed, to reduce the excessive vibrations at the critical speeds. The vibration monitoring during startup or shutdown has been receiving growing attention (ref. 1), especially for machines such as aircraft engines, which are subjected to frequent starts and stops, as well as high speeds and acceleration rates. It has been recognized that the presence of angular acceleration strongly affects the rotor's maximum response to unbalance and the speed at which it occurs. Unfortunately, conventional nondestructive evaluation (NDE) methods have unacceptable limits in terms of their application for online crack detection. Some of these techniques are time consuming and inconvenient for turbomachinery service testing. Almost all of these techniques require that the vicinity of the damage be known in advance, and they can provide only local information, with no indication of the structural strength at a component or system level. In addition, the effectiveness of these experimental techniques is affected by the high measurement noise levels existing in complex turbomachine structures. Therefore, the use of vibration monitoring along with vibration analysis has been receiving increasing attention.

Sawicki, Jerzy T.↗

Assessment of Flow-Enhanced Electrochemical Sensor Testing and Deployments for MSRs

This report serves as the deliverable for Milestone M3RS-23AN0401061 that is part of Work Package RS-23AN040106 (Flow Enhanced Sensors for MSRs – ANL). The goal of this milestone was to determine performance of the flow enhanced electrochemical sensor (FEES) and modular flow instrumentation testbed (MFIT) in safeguards relevant scenarios. Flow enhanced electrochemical sensors are a type of electroanalytical sensor that has been developed at Argonne National Laboratory to be installed directly into MSR flow conduits to make measurements of the salt composition. These sensors represent a significant improvement in capabilities compared to earlier electroanalytical sensors that instead can only be operated in quiescent conditions. Previous work has focused on testing of the FEES in flowing conditions provided by the MFIT to assess the accuracy and precision of the sensor measurements. To further improve this capability, in FY23 we undertook a campaign of safeguards relevant scenarios in molten salt containing a range of uranium chloride concentrations (0 to 3 wt%). All the testing carried out in FY23 was aided by a control system designed to automatically actuate flow conditions and collect data. This new automation system is estimated to have increased experimental throughput by a factor of four and enabled testing in a variety of complex conditions. The advancements in throughput and repeatability led to improved quantification of actinide concentrations using the in-flow sensors, with a reduction of the mean absolute relative error from 5.6% in FY22 to 3.1% in FY23. In addition to safeguards scenarios run in the MFIT, FY23 work included deployment of a FEES at a partner institution where it will be tested in a flowing salt loop. The FEES was successfully integrated into that loop and is being tested prior to loop startup. In FY23, work also continued on the smaller flow system that we have named the mini-MFIT. This smaller system is capable of rapid prototyping of new sensor designs prior to installation in the larger MFIT radiological flow system. Work was carried out to test this new system in non-radiological molten salts in a separate glovebox. This work is helping us to enhance the accuracy of our salt monitoring capabilities through the integration of multiple types of sensors. The high degree of accuracy required by 10 CFR 74 represents a significant challenge, and further design evolution and integration of the sensors into multimodal sensing frameworks will be needed to further push the measurement accuracy to the needed level.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Cyber-Physical Simulation of the Cold Startup of Solid Oxide Fuel Cell – Gas Turbine (SOFC-GT) Hybrid Systems

This work introduces experimental studies for the cold startup process (CPS) of the SOFC-GT hybrid system using the cyber-physical simulation approach. The physical gas turbine is coupled with a cyber-physical SOFC stack, which is represented using the integration of a real time dynamic SOFC model with physical components (e.g., pressure chamber, natural gas burner, etc.). Different ramp rates of the turbine speed were tested out during the startup processes. Bypass valves were also used to manipulate the airflow during SOFC-GT hybrid system start-up process. Different ramp rates enable the rapid start-up of the turbine to avoid surge and stall, meanwhile enable acceptable warm rate of the fuel cell stack without damaging the cell material. CPS can enable dynamic characterizations of highly integrated systems at lower cost.

Zhou, Nana↗