Research Achievements Review, volume II
Materials research - diffusion bonding methods, stress corrosion tests, nondestructive testing, material designs for electronic equipment, and nonmetallic material development.
SPACECRAFT COMPONENT↗
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Materials Characterization and Testing support
PowerPoint Slides for Materials Characterization and Testing support
36 - MATERIALS SCIENCE↗
Ultra-Fast Fracture Strength of Advanced Ceramics at Elevated Temperatures
An attempt was made to determine elevated-temperature, 'ultra'-fast fracture strengths of one alumina, two silicon nitrides and one silicon carbide by using constant stress-rate ('dynamic fatigue') testing with a series of 'ultra'-fast test rates. Of the materials tested, the alumina exhibited a convergence of strength at stress rates below 3.3 x 10(exp 4) MPa/s. The strength approached approximately the room-temperature inert strength. By contrast, the silicon nitrides and silicon carbide did not reveal a strength approach, but exhibited elevated-temperature strengths 10 and 20% lower than their respective room-temperature strengths. Although the analytical results imply that the elevated-temperature 'inert' strength of a ceramic material can be obtained by using sufficiently high stress rates, the experimental testing rates were only sufficient to demonstrate convergence for the alumina.
Choi, Sung R.↗
Measurement and Reporting Guidelines for Solar Mirror Aging Tests Using Xenon Arc Lamp Exposure (XALE)
This technical report provides a guideline for accelerated aging tests on solar reflectors. Solar reflectors must have a high durability, with goal lifespans reaching 30 years. To test and develop state-of-the-art solar reflectors, relevant durability tests must be conducted. Existing guidelines for materials testing include isothermal testing, humidity testing, corrosion, etc., but many tests do not specify to include solar irradiance or address its relevance to solar reflector durability. The guideline focuses on test design and reporting guidelines for using Xenon Arc Lamp Exposure (XALE). The XALE environmental chambers can subject samples to a combination of relevant environmental factors including concentrated solar irradiance, heat, humidity, and weathering cycles. The guideline is meant to provide information on developing relevant test conditions, exposure times, reflectance characterization procedures, and data reporting.
14 SOLAR ENERGY↗
Film Deposition, Cryogenic RF Testing and Materials Analysis of a Nb/Cu Single Cell SRF Cavity
In this study, we present preliminary results on using a cathodic-arc-discharge Nb plasma ion source to establish a Nb film-coated single-cell Cu cavity for SRF research. The polycrystalline Cu cavity was fabricated and mirror-surface-finished by a centrifugal barrel polishing (CBP) process at Jefferson Lab. Special pre-coating processes were conducted, in order to create a template-layer for follow-on Nb grain thickening. A sequence of cryogenic RF testing demonstrated that the Nb film does show superconductivity. But the quality factor of this Nb/Cu cavity is low as a result of high residual surface resistance. We are conducting a thorough materials characterization to explore if some microstructural defects or hydrogen impurities, led to such a low quality factor.
Zhao, Xin↗
Testing of aircraft passenger seat cushion materials. Full scale, test description and results, volume 1
Eight different seat cushion configurations were subjected to full-scale burn tests. Each cushion configuration was tested twice for a total of sixteen tests. Two different fire sources were used. They consisted of one liter of Jet A fuel for eight tests and a radiant energy source with propane flame for eight tests. Both fire sources were ignited by a propane flame. During each test, data were recorded for smoke density, cushion temperatures, radiant heat flux, animal response to combustion products, rate of weight loss of test specimens, cabin temperature, and for the type and content of gas within the cabin atmosphere. When compared to existing passenger aircraft seat cushions, the test specimens incorporating a fire barrier and those fabricated from advanced materials, using improved construction methods, exhibited significantly greater fire resistance.
Schutter, K. J.↗
A One-Piece Lunar Regolith-Bag Garage Prototype
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: VectranTM, NextelTM, Gore PTFE FabricTM, ZylonTM TwaronTM and NomexTM. Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of KevlarTM and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelty mockups with each iteration, and to conduct appropriate tests of the structure.
Smithers, Gweneth A.↗
A One-Piece Lunar Regolith-Bag Garage Prototype
Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. We designed and constructed a prototype for a one-piece regolith-bag unpressurized garage concept, and, in parallel, we conducted a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. In our concept, a lightweight fabric form is launched from Earth to be landed on the lunar surface and robotically filled with raw lunar regolith. In the materials testing program, regolith-bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and, within our current means, we also performed these tests under cold and elevated temperatures. In some cases, lunar simulant (JSC-1) was used in conjunction with testing. Our ambition is to continuously refine our testing to reach lunar environmental conditions to the extent possible. A series of preliminary structures were constructed during design of the final prototype. Design is based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite (fairly close to the weight of lunar regolith on the moon). The structure is free-standing, but has not yet been load tested. Our plan for the future would be to construct higher fidelity mockups with each iteration, and to conduct appropriate tests of the structure.
Smithers, Gweneth A.↗
2013 Caliban and Prospero experiments for the study of the behavior of radiation protection instrumentations in case of a criticality accident - 14346
Experiments using the CALIBAN and PROSPERO reactors were performed in 2013 in the framework of a collaboration between IRSN and CEA. The objective was to provide data about the possibility to use information given by radiation protection instrumentations (RPI) in the case of a criticality accident. In that purpose, the behavior of RPI was studied for various kinetics of the reactors which simulated different starts of a criticality accident. The article presents the safety issues associated with these experiments, i.e. the possible use of information given by the RPI for the emergency response of a criticality accident (detection of the accident, triage of the personnel, follow-up of the accident and reentry). Then, one paragraph is dedicated to the presentation of the tested material. In addition, the CALIBAN and PROSPERO reactors are briefly described, followed by the performed experiments. The RPI are neither designed nor dedicated to be used in case of a criticality accident. However, the preliminary conclusion of the experiments performed in 2013 is that the tested RPI have a correct behavior for slow kinetic experiments performed with the PROSPERO reactor, but might give less reliable and accurate information for pulse experiments performed with the CALIBAN reactor. In the last case, they can nevertheless provide information that can be helpful for the emergency response and the limitation of the consequences of the criticality accident. However, if the RPI are included in the emergency response of a criticality accident (detection, triage, follow-up, reentry), emergency procedures should be adapted. Other experiments might be performed in order to confirm results and to extend the number of tested materials, in particular portable survey meters or contamination area monitors. (authors)
42 ENGINEERING↗
Operating characteristics, velocity and Pitot distribution, and material evaluation tests in the Langley one-inch-square plasma accelerator.
Performance and operation of one-inch-square plasma accelerator to simulate reentry velocities
VELOCITY MEASUREMENT↗
Unmanned Vehicle Material Flammability Test
Microgravity combustion phenomena have been an active area of research for the past 3 decades however, there have been very few experiments directly studying spacecraft fire safety under low-gravity conditions. Furthermore, none of these experiments have studied sample and environment sizes typical of those expected in a spacecraft fire. All previous experiments have been limited to samples of the order of 10 cm in length and width or smaller. Terrestrial fire safety standards for all other habitable volumes on earth, e.g. mines, buildings, airplanes, ships, etc., are based upon testing conducted with full-scale fires. Given the large differences between fire behavior in normal and reduced gravity, this lack of an experimental data base at relevant length scales forces spacecraft designers to base their designs using 1-g understanding. To address this question a large scale spacecraft fire experiment has been proposed by an international team of investigators. This poster presents the objectives, status and concept of this collaborative international project to examine spacecraft material flammability at realistic scales. The concept behind this project is to utilize an unmanned spacecraft such as Orbital Cygnus vehicle after it has completed its delivery of cargo to the ISS and it has begun its return journey to earth. This experiment will consist of a flame spread test involving a meter scale sample ignited in the pressurized volume of the spacecraft and allowed to burn to completion while measurements are made. A computer modeling effort will complement the experimental effort. Although the experiment will need to meet rigorous safety requirements to ensure the carrier vehicle does not sustain damage, the absence of a crew removes the need for strict containment of combustion products. This will facilitate the examination of fire behavior on a scale that is relevant to spacecraft fire safety and will provide unique data for fire model validation. This will be the first opportunity to examine microgravity flame behavior at scales approximating a spacecraft fire.
Combustion↗
Measurement of the forming limit stress curve using a multi-axial tube expansion test with a digital image correlation system
A servo-controlled tension-internal pressure testing machine with an optical 3D deformation analysis system (ARAMIS) was used to measure the multi-axial plastic deformation behavior of a high-strength steel sheet for a range of strain from initial yield to fracture. The testing machine is capable of applying arbitrary principal stress or strain paths to a tubular specimen using an electrical, closed-loop servo-control system for axial force and internal pressure. Tubular specimens with an inner diameter of 44.6 mm were fabricated from a high-strength steel sheet with a tensile strength of 590 MPa and a thickness of 1.2 mm by roller bending and laser welding. Several linear and non-linear stress paths in the first quadrant of the stress space were applied to the tubular specimens in order to measure the forming limit curve (FLC) and forming limit stress curve (FLSC) of the as-received test material, in addition to the contours of plastic work and the directions of plastic strain rates. The contours of plastic work and the directions of plastic strain rates measured for the linear stress path experiments were compared with those calculated using selected yield functions in order to identify the most appropriate yield function for the test material. Moreover, a Marciniak-Kuczyński type (M-K) forming limit analysis was performed using the most appropriate yield function. The calculated and measured FLC and FLSC were compared in order to validate the M-K approach. The path-dependence of the FLC and FLSC was also investigated.
97 MATHEMATICS AND COMPUTING↗
Results of Pioneer 10 and 11 meteoroid experiments - Interplanetary and near-Saturn
The meteoroid penetration detectors on Pioneer 10 (channel 0) recorded 95 penetrations through the 25-micron stainless steel test material while the spacecraft was between 1 and 18 AU. The spatial density of 10 to the -9 g meteoroids is found to be essentially constant between 1 and 18 AU. The meteoroid penetration detectors on Pioneer 11 recorded 87 penetrations (55 on channel 0 and 32 on channel 1) through the 50-micron stainless steel test material while the spacecraft was between 1 and 9 AU. It is found that the meteoroids between 4 and 5 AU are not in direct circular or near-circular orbits near the ecliptic plane. The Pioneer 11 data obtained between 4 and 5 AU are best explained by the meteoroids being in randomly inclined orbits of high eccentricity. If meteoroids are in these cometlike orbits, the great increase in penetration flux previously measured near Jupiter with the Pioneer 10 experiment cannot be attributed to gravitational focusing unless the size distribution of meteoroids changes substantially between 1 and 5 AU. At Saturn encounter, the penetration flux increased by about three orders of magnitude, probably as the result of impacts from ring particles. Saturn's ring E is estimated to be 1800 km thick with an optical thickness greater than 10 to the -8.
Humes, D. H.↗
Pulsed source of energetic atomic oxygen
A pulsed high flux source of nearly monoenergetic atomic oxygen was designed, built, and successfully demonstrated. Molecular oxygen at several atmospheres pressure is introduced into an evacuated supersonic expansion nozzle through a pulsed molecular beam valve. An 18 J pulsed CO2 TEA laser is focused to intensities greater than 10(9) W/sq cm in the nozzle throat to generate a laser-induced breakdown. The resulting plasma is heated in excess of 20,000 K by a laser supported detonation wave, and then rapidly expands and cools. Nozzle geometry confines the expansion to provide rapid electron-ion recombination into atomic oxygen. Average O atom beam velocities from 5 to 13 km/s were measured at estimated fluxes to 10(18) atoms per pulse. Preliminary materials testing has produced the same surface oxygen enrichment in polyethylene samples as obtained on the STS-8 mission. Scanning electron microscope examinations of irradiated polymer surfaces reveal an erosion morphology similar to that obtained in low Earth orbit, with an estimated mass removal rate of approx. 10(-24) cu cm/atom. The characteristics of the O atom source and the results of some preliminary materials testing studies are reviewed.
Caledonia, George E.↗
Acoustic sensors for fission gas characterization: R and D skills devoted to innovative instrumentation in MTR, non-destructive devices in hot lab facilities and specific transducers for measurements of LWR rods in nuclear plants
First of all, we will present the main principle of the method. A piezoelectric transducer, driven by a pulse generator, generates the acoustic waves in a cavity that may be the fuel rod or a chamber connected to an instrumented rod. The composition determination consists in measuring the time of flight of the acoustic signal emitted. The pressure can be estimated by a calibration process, above the measurement of the amplitude of the signal. Two projects will then be detailed. The first project consists in the development of advanced instrumentation for in-pile experiments in Material Testing Reactor. It constitutes a main goal for the improvement of the nuclear fuel behavior knowledge. This acoustic method was tested with success during a first experiment called REMORA 3, and the results were used to differentiate helium and fission gas release kinetics under transient operating conditions. This experiment was lead at OSIRIS reactor (CEA Saclay, France). As a first step of the development program, we performed in-pile tests on the most sensitive component, i.e., the piezoelectric transducer. For this purpose, the active part of this sensor has been qualified on gamma and neutron radiations and at high temperature. Various industrial piezo-ceramics were exposed to a high activity Cobalt source for few days. The cumulated dose was ranged from 50 kGy up to 2 MGy. Next, these devices were placed inside a Material Test Reactor to investigate their reliability towards neutron fluence. The final fluence after 150 days of irradiation was up to 1.6.10{sup 21}n/cm{sup 2} (for thermal neutron). Irreversible variations have been measured. Next, a specific sensor has been implemented on an instrumented fuel rod and tested in the frame of a REMORA 3 Irradiation test. It was the first experiment under high mixed, temperature neutron and gamma flux. A first irradiation phase took place in March 2010 in the OSIRIS reactor and in November 2010 for the second step of the irradiation. The instrumented fuel rod incorporating the ultrasonic gas composition sensor was finally irradiated during 2 weeks in nominal conditions. Neutronics calculation will be performed in order to calculate the thermal and fast neutron fluence and the gamma dose absorbed by acoustic sensor. A first evaluation gives a thermal fluence about 4,5.10{sup 19} n/cm{sup 2}, a fast neutrons fluence about 4,5.1018 n/cm{sup 2} and a total gamma dose up to 0,25 MGy The maximal temperature during the irradiation test was about 150 C. Although the ultrasonic sensor appears to be damaged, the optimization of the electrical attack parameters and the development of a new signal processing maintain the measurement feasibility up the end of the irradiation campaign. It was the first time that the composition of fission gas has been monitored all along an irradiation experiment in a MTR, giving access to the gas release kinetics. New researches involve thick film transducers produced by screen-printing process in order to propose piezoelectric structures for harsh temperature and irradiation measurements. The second project consists in the development of a non-destructive device that can be directly applied on a LWR fuel rod. The problem to be solved relates to the measurement of the fission gas pressure and composition in a fuel rod using a non-destructive method. Fuel rod internal pressure is one of the safety criteria applied in nuclear power analyses. This criterion must be verified in order to avoid any fuel-cladding gap reopening risk and therefore any local clad ballooning. Apart from the safety implications, this parameter is also a fuel behaviour indicator and reflects the overall fuel performance in operation, but also during shipping and long-term storage. Rod internal pressure is one criterion amongst others, like cladding corrosion, against which the acceptable fuel burn-up limit is set. A sensor has been achieved in 2007. A full-scale hot cell test of the internal gas pressure and composition measurement by an acoustic sensor was conducted successfully between 2008 and 2010 on 5 high burn-up MOX fuel rods and 2 very high burn-up UO{sub 2} fuel rods in LECA Facility at Cadarache Centre. An improvement of this sensor has been proposed, allowing us to divide by two the uncertainty on the pressure measurement. In the case of hot-cell measurements, viscous liquid can be used to couple the sensor with the rod. For gas content with a pressure exceeding 15 bars and a 10% Xe/Kr ratio, such coupling may reduce relative acoustic method accuracy by ±7% for pressure measurement result and ±0.25 % for the assessment of gas composition. These results make it possible to demonstrate the feasibility of the technique on LWR fuel rods. The transducer and the associated methodology are now operational for non-destructive measurements in hot lab facilities and allow characterising the fission gas without puncturing the fuel rods. Up to now, any other non-destructive method can be proposed. A next step will be the development of an industrial application in a fuel storage pool in order to perform a large number of measurements on a fuel assembly in nuclear plants.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Comparison of steady and transient flow boiling critical heat flux for FeCrAl accident tolerant fuel cladding alloy, Zircaloy, and Inconel
Steady and transient (with a heating rate of 685?/s) internal-flow CHF (Critical Heat Flux) experiments were conducted under atmospheric pressure at a fixed inlet temperature (40? or 60?) and mass flow (300kg/m 2 s) on Fe-13Cr-6Al alloy, Inconel 600 and Zircaloy-4 tube samples. Multiple experiments were repeated on the same specimen to investigate the effect of surface characteristic changes (i.e., roughness, wettability, and oxide scale morphology) on the occurrence of CHF. Despite notable changes of wettability, roughness, and oxide layer characteristics on samples that had already been subjected to CHF, measured flow CHF remained unchanged throughout repeated experiments for tested materials. This demonstrates that the surface effects on flow CHF are limited in the test conditions. In the steady-state flow boiling condition, Fe-13Cr-6Al alloy demonstrated a 22% and 14% increase in CHF compared to Zircaloy-4 and Inconel 600, respectively. Compared to the 2006 Groeneveld CHF lookup table, Fe-13Cr-6Al alloy gives a 13% increase in the tested flow boiling condition. Material properties are considered primarily responsible for the observed CHF differences among the tested materials. The surface thermal economy parameter $\frac{(pc_p)^{3/2}}{\sqrt{k}}$ is proposed as an explanation for the observed CHF differences; this parameter is related to material’s ability to avoid an irreversible dry spot formation. The apparent disagreement of Zircaloy-4 CHF with both the look up table predictions and Inconel 600 shows the limitation of departure of nuclate boiling (DNB) evaluations that do not consider cladding materials. The transient Fe-13Cr-6Al CHF is 39% and 23% higher than the lookup table prediction and the steady-state condition experimental result, respectively.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Physical and chemical test results of electrostatic safe flooring materials
This test program was initiated because a need existed at the Kennedy Space Center (KSC) to have this information readily available to the engineer who must make the choice of which electrostatic safe floor to use in a specific application. The information, however, should be of value throughout both the government and private industry in the selection of a floor covering material. Included are the test results of 18 floor covering materials which by test evaluation at KSC are considered electrostatically safe. Tests were done and/or the data compiled in the following areas: electrostatics, flammability, hypergolic compatibility, outgassing, floor type, material thickness, and available colors. Each section contains the test method used to gather the data and the test results.
Gompf, R. H.↗
Quantitative description of microstructure defects in hexagonal boron nitrides using X-ray diffraction analysis
A routine for simultaneous quantification of turbostratic disorder, amount of puckering and the dislocation and stacking fault density in hexagonal materials was proposed and tested on boron nitride powder samples that were synthesised using different methods. The routine allows the individual microstructure defects to be recognised according to their effect on the anisotropy of the X-ray diffraction line broadening. For quantification of the microstructure defects, the total line broadening is regarded as a linear combination of the contributions from the particular defects. The total line broadening is obtained from the line profile fitting. As testing material, graphitic boron nitride (h-BN) was employed in the form of hot-isostatically pressed h-BN, pyrolytic h-BN or a h-BN, which was chemically vapour deposited at a low temperature. The kind of the dominant microstructure defects determined from the broadening of the X-ray diffraction lines was verified by high resolution transmission electron microscopy. Their amount was attempted to be verified by alternative methods. - Highlights: • Reliable method for quantification of microstructure defects in BN was suggested. • The method is based on the analysis of anisotropic XRD line broadening. • This XRD line broadening is unique and characteristic of the respective defect. • Thus, the quantification of coexistent microstructure defects is possible. • The method was tested on hexagonal BN, which was produced by different techniques.
36 MATERIALS SCIENCE↗