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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
NASA NTRS2022

NASA Ground-based Layered Pressure Vessels Materials Report

A significant portion of Layered Pressure Vessels (LPVs) manufactured for NASA in the 1950s and ’60s are of non-code construction. These vessels were constructed to the standards of individual manufacturers rather than an industry or consensus standard and often contain legacy or proprietary materials, which have poor or no characterization. Obtaining correct material properties is the first step in assuring vessel safety and predicting life and critical failure modes before they happen. This report details the efforts of the LPV Project related to material properties and characterization. The goal in testing materials from deconstructed vessels was to provide material characterization utilizing modern test methods that would give a strong probabilistic base as an option for future analysis. ASTM E1820, Standard Test Method for Measurement of Fracture Toughness was used for fracture toughness; ASTM E1921, Standard Test Method for Determination of Reference Temperature, T0, for Ferritic Steels in the Transition Range for transition temperature; and ASTM E647, Standard Test Method for Measurement of Fatigue Crack Growth Rates for fatigue crack growth. Particular focus was placed on determination of transition temperature through evaluation of the T0 reference temperature in accordance with ASTM E1921. Transition temperature testing allows for a probabilistic analysis of vessel materials that may be operating at temperatures below the transition from ductile tearing to brittle cleavage failure. This test method was not available at the time of construction and has proved invaluable to the characterization of older ferritic steels. The values reported are specific to the largest body of materials found in the current NASA fleet, but do not claim to be all inclusive. As demonstrated in this report, some materials contain extreme lot-to-lot variability. In some cases, this can be comfortably bounded by worst case probabilistic methods, however it is always recommended that vessel specific data be collected in as much depth as possible to ensure correct assumptions and avoid unduly restricting vessel usage.

Layered Pressure Vessel↗
NASA NTRS1975

Quarantine testing and biocharacterization of lunar materials

Quarantine testing was conducted to ensure the safety of all life on earth. The plants and animals which were exposed to lunar material were carefully observed for prolonged periods to determine if any mutation or changes in growing characteristics and behavior occurred. The quarantine testing was terminated after the Apollo 14 flight when it became apparent that previously returned lunar material contained no potentially harmful agents. Further biological experimentation with the lunar material was conducted to determine its chemical, physical, and nutritional qualities.

Gerald R. Taylor↗
NASA NTRS2006

Method and apparatus for testing surface characteristics of a material

A method, apparatus and system for testing characteristics of a material sample is provided. The system includes an apparatus configured to house the material test sample while defining a sealed volume against a surface of the material test sample. A source of pressurized fluid is in communication with, and configured to pressurize, the sealed volume. A load applying apparatus is configured to apply a defined load to the material sample while the sealed volume is monitored for leakage of the pressurized fluid. Thus, the inducement of surface defects such as microcracking and crazing may be detected and their effects analyzed for a given material. The material test samples may include laminar structures formed of, for example, carbon cloth phenolic, glass cloth phenolic, silica cloth phenolic materials or carbon-carbon materials. In one embodiment the system may be configured to analyze the material test sample while an across-ply loading is applied thereto.

Johnson, David L.↗
DOE OSTI2010

Ideal MHD stability of a spherical tokamak power plant and a component test facility.

We have investigated ideal MHD stability of two advanced spherical tokamak confinement concepts: the spherical tokamak power plant (STPP), a 3 GW concept fusion power plasma producing 1 GW of electric power, and the component test facility (CTF), a concept designed for in situ materials testing for ITER and beyond. Detailed stability studies for toroidal mode number n = 1, 2, 3 displacements are presented as a function of conformal wall radius R{sub w} and on-axis safety factor q{sub 0}. For the STPP marginal stability scans held the current profile fixed, but varied the total plasma current. For the CTF we have extended and parallelized earlier marginal stability scans to scan over both the plasma beta and q{sub 0} by varying the current profile to preserve the total plasma current. These confirm that both concepts are stable provided that the wall is sufficiently close and q{sub 0} sufficiently large (q{sub 0} > 2.8 for the power plant and q{sub 0} > 2.1 for the CTF). Both power plant and CTF configurations are found to be ballooning stable.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Enhancing Post-Irradiation Examination (PIE) Efficiency with High-Throughput Experiments

Nuclear materials testing is essential for understanding changes in reactor environments, but traditional methods are costly and time-consuming. High-Throughput Experimentation (HTE) enables rapid screening and optimization of material properties by significantly increasing the number of specimens in the experiment. In this work, HTE methods were employed to irradiate novel materials at the Advanced Test Reactor (ATR) at Idaho National Laboratory. A total of 367 sub-sized tensile specimens were irradiated using the standard capsule design. To facilitate HTE, automated systems such as the Automated Mechanical Testing System were implemented for mechanical testing within hot cell environments, thereby reducing the need for manual interaction with hot cell manipulators and significantly lowering both the cost and duration of experiments. Digital image correlation (DIC) was used to measure displacement during mechanical testing, providing precise, non-contact measurement capabilities. The methodologies developed in this research will support the advancement of HTE techniques for future nuclear materials testing experiments at ATR. This approach allows for more efficient and cost-effective evaluation of new materials, ultimately leading to improved reactor performance, enhanced safety, and extended longevity within the nuclear industry.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2000

Burning Plastics Investigated in Space for Unique US/Russian Cooperative Project

It is well known that fires in the low-gravity environment of Earth-orbiting spacecraft are different from fires on Earth. The flames lack the familiar upward plume, which is the result of gravitational buoyancy. These flames, however, are strongly influenced by minor airflow currents. A recent study conducted in low gravity (microgravity) on the Russian orbital station Mir used burning plastic rods mounted in a small chamber with a controllable fan to expose the flame to airflows of different velocities. In this unique project, a Russian scientific agency, the Keldysh Research Center, furnished the apparatus and directed the Mir tests, while the NASA Glenn Research Center at Lewis Field provided the test materials and the project management. Reference testing and calibrations in ground laboratories were conducted jointly by researchers at Keldysh and at the NASA Johnson Space Center's White Sands Test Facility. Multiple samples of three different plastics were burned in the tests: Delrin, a common material for valve bodies; PMMA, a plastic "glass"; and polyethylene, a familiar material for containers and films. Each burned with a unique spherical or egg-shaped flame that spread over the rod. The effect of varying the airflow was dramatic. At the highest airflow attainable in the combustion chamber, nearly 10 cm/sec (a typical ventilation breeze), the flames were bright and strong. As airflow velocity decreased, the flames became shorter but wider. In addition, the flames became less bright, and for PMMA and polyethylene, they showed two colors, a bright part decreasing in volume and a nearly invisible remainder (see the photographs). Finally, at a very low velocity, the flames extinguished. For the plastics tested, this minimum velocity was very low, around 0.3 to 0.5 cm/sec. This finding confirms that at least a slight airflow is required to maintain a flame in microgravity for these types of materials.

Friedman, Robert↗
NASA NTRS2006

Electrical Arc Ignition Testing of Spacesuit Materials

A viewgraph presentation on electrical arc ignition testing of spacesuit materials is shown. The topics include: 1) Background; 2) Test Objectives; 3) Test Sample Materials; 4) Test Methods; 5) Scratch Test Objectives; 6) Cotton Scratch Test Video; 7) Scratch Test Results; 8) Entire Date Plot; 9) Closeup Data Plot; 10) Scratch Test Problems; 11) Poke Test Objectives; 12) Poke Test Results; 13) Poke Test Problems; 14) Wire-break Test Objectives; 15) Cotton Wire-Break Test Video; 16) High Speed Cotton Wire-break Test Video; 17) Typical Data Plot; 18) Closeup Data Plot; 19) Wire-break Test Results; 20) Wire-break Tests vs. Scratch Tests; 21) Urethane-coated Nylon; and 22) Moleskin.

Smith, Sarah↗
DOE OSTI2011

Development of rapid, continuous calibration techniques and implementation as a prototype system for civil engineering materials evaluation

Until recently, civil engineering material calibration data could only be obtained from material sample cores or via time consuming, stationary calibration measurements in a limited number of locations. Calibration data are used to determine material propagation velocities of electromagnetic waves in test materials for use in layer thickness measurements and subsurface imaging. Limitations these calibration methods impose have been a significant impediment to broader use of nondestructive evaluation methods such as ground-penetrating radar (GPR). In 2006, a new rapid, continuous calibration approach was designed using simulation software to address these measurement limitations during a Federal Highway Administration (FHWA) research and development effort. This continuous calibration method combines a digitally-synthesized step-frequency (SF)-GPR array and a data collection protocol sequence for the common midpoint (CMP) method. Modeling and laboratory test results for various data collection protocols and materials are presented in this paper. The continuous-CMP concept was finally implemented for FHWA in a prototype demonstration system called the Advanced Pavement Evaluation (APE) system in 2009. Data from the continuous-CMP protocol is processed using a semblance/coherency analysis to determine material propagation velocities. Continuously calibrated pavement thicknesses measured with the APE system in 2009 are presented. This method is efficient, accurate, and cost-effective.

42 ENGINEERING↗
NASA NTRS1991

Comparison of Weibull strength parameters from flexure and spin tests of brittle materials

Fracture data from five series of four point bend tests of beam and spin tests of flat annular disks were reanalyzed. Silicon nitride and graphite were the test materials. The experimental fracture strengths of the disks were compared with the predicted strengths based on both volume flaw and surface flaw analyses of four point bend data. Volume flaw analysis resulted in a better correlation between disks and beams in three of the five test series than did surface flaw analysis. The Weibull (moduli) and characteristic gage strengths for the disks and beams were also compared. Differences in the experimental Weibull slopes were not statistically significant. It was shown that results from the beam tests can predict the fracture strength of rotating disks.

Holland, Frederic A., Jr.↗
NASA NTRS1993

Micromechanical simulation of damage progression in carbon phenolic composites

Carbon/phenolic composites are used extensively as ablative insulating materials in the nozzle region of solid rocket motors. The current solid rocket motor (RSRM) on the space shuttle is fabricated from woven rayon cloth which is carbonized and then impregnated with the phenolic resin. These plies are layed up in the desired configuration and cured to form the finished part. During firing, the surface of the carbon/phenolic insulation is exposed to 5000 F gases from the rocket exhaust. The resin pyrolizes and the material chars to a depth which progresses with time. The rate of charring and erosion are generally predictable, and the insulation depth is designed to allow adequate safety margins over the firing time of the motor. However, anomalies in the properties and response of the carbon/phenolic materials can lead to severe material damage which may decrease safety margins to unacceptable levels. Three macro damage modes which were observed in fired nozzles are: ply lift, 'wedge out', and pocketing erosion. Ply lift occurs in materials with plies oriented nearly parallel to the surface. The damage occurs in a region below the charred material where material temperatures are relatively low - about 500 F. Wedge out occurs at the intersection of nozzle components whose plies are oriented at about 45 deg. The corner of the block of material breaks off along a ply interface. Pocketing erosion occurs in material with plies oriented normal to the surface. Thermal expansion is restrained in two directions resulting in large tensile strains and material failure normal to the surface. When a large section of material is removed as a result of damage, the insulation thickness is reduced which may lead to failure of the nozzle due to excessive heating of critical components. If these damage events cannot be prevented with certainty, the designer must increase the thickness of the insulator thus adding to both weight and cost. One of the difficulties in developing a full understanding of these macro damage mechanisms is that the loading environment and the material response to that environment are extremely complex. These types of damage are usually only observed in actual motor firings. Therefore, it is difficult and expensive to evaluate the reliability of new materials. Standard material tests which measure mechanical and thermal properties of test specimens can only provide a partial picture of how the material will respond in the service environment. The development of the ANALOG test procedure which can combine high heating rates and mechanical loads on a specimen will improve the understanding of the interactive effects of the various loads on the system. But a mechanistic model of material response which can account for the heterogeneity of the material, the progression of various micromechanical damage mechanisms, and the interaction of mechanical and thermal stresses on the material is required to accurately correlate material tests with response to service environments. A model based on fundamental damage mechanisms which is calibrated and verified under a variety of loading conditions will provide a general tool for predicting the response of rocket nozzles. The development of a micromechanical simulation technique was initiated and demonstrated to be effective for studying across-ply tensile failure of carbon/phenolic composites.

Slattery, Kerry T.↗
DOE OSTI2012

Examination of a Size-Change Test for Photovoltaic Encapsulation Materials: Preprint

We examine a proposed test standard that can be used to evaluate the maximum representative change in linear dimensions of sheet encapsulation products for photovoltaic modules (resulting from their thermal processing). The proposed protocol is part of a series of material-level tests being developed within Working Group 2 of the Technical Committee 82 of the International ElectrotechnicalCommission. The characterization tests are being developed to aid module design (by identifying the essential characteristics that should be communicated on a datasheet), quality control (via internal material acceptance and process control), and failure analysis. Discovery and interlaboratory experiments were used to select particular parameters for the size-change test. The choice of a sandsubstrate and aluminum carrier is explored relative to other options. The temperature uniformity of +/- 5C for the substrate was confirmed using thermography. Considerations related to the heating device (hot-plate or oven) are explored. The time duration of 5 minutes was identified from the time-series photographic characterization of material specimens (EVA, ionomer, PVB, TPO, and TPU). Thetest procedure was revised to account for observed effects of size and edges. The interlaboratory study identified typical size-change characteristics, and also verified the absolute reproducibility of +/- 5% between laboratories.

14 SOLAR ENERGY↗
NASA NTRS1987

Fatigue testing a plurality of test specimens and method

Described is a fatigue testing apparatus for simultaneously subjecting a plurality of material test specimens to cyclical tension loading to determine the fatigue strength of the material. The fatigue testing apparatus includes a pulling head having cylinders defined therein which carry reciprocating pistons. The reciprocation of the pistons is determined by cyclical supplies of pressurized fluid to the cylinders. Piston rods extend from the pistons through the pulling head and are attachable to one end of the test specimens, the other end of the test specimens being attachable to a fixed base, causing test specimens attached between the piston rods and the base to be subjected to cyclical tension loading. Because all the cylinders share a common pressurized fluid supply, the breaking of a test specimen does not substantially affect the pressure of the fluid supplied to the other cylinders nor the tension applied to the other test specimens.

Hodo, James D.↗
DOE OSTI2015

Monte-Carlo Simulations of the Nuclear Energy Deposition Inside the CARMEN-1P Differential Calorimeter Irradiated into OSIRIS Reactor

The nuclear heating measurements in Material Testing Reactors (MTRs) are crucial for the study of nuclear materials and fuels under irradiation. The reference measurements of this nuclear heating are especially performed by a differential calorimeter including a graphite sample material. These measurements are then used for other experimental conditions in order to predict the nuclear heating and thermal conditions induced in the irradiation devices. Nuclear heating is a great deal of interest at the moment as the measurement of such heating is an important issue for MTRs reactors. This need is especially generated by the new Jules Horowitz Reactor (JHR), under construction at CEA/Cadarache 'French Alternative Energies and Atomic Energy Commission'. This new reactor, that will be operational in late 2019, is a new facility for the nuclear research on materials and fuels. Indeed the expected nuclear heating rate is about 20 W/g for nominal capacity of 100 MW. The present Monte Carlo calculation works belong to the IN-CORE (Instrumentation for Nuclear radiation and Calorimetry On line in Reactor): a joint research program between the CEA and Aix- Marseille University in 2009. One scientific aim of this program is to design and develop a multi-sensors device, called CARMEN, dedicated to the measurements of main physical parameters simultaneously encountered inside JHR's experimental channels (core and reflector) such as neutron fluxes, photon fluxes, temperature, and nuclear heating. A first prototype was already developed. This prototype includes two mock-ups dedicated respectively to neutronic measurements (CARMEN-1N) and to photonic measurements (CARMEN-1P) with in particular a specific differential calorimeter. Two irradiation campaigns were performed successfully in the periphery of OSIRIS reactor (a MTR located at Saclay, France) in 2012 for nuclear heating levels up to 2 W/g. First Monte Carlo calculations reduced to the graphite sample of the calorimeter were carried out. A preliminary analysis shows that the numerical results overestimate the measurements by about 20 %. A new approach has been developed in order to estimate the nuclear heating by two methods (energy deposition or KERMA) by considering the whole complete geometry of the sensor. This new approach will contribute to the interpretation of the irradiation campaign and will be useful to improve the out-of-pile calibration procedure of the sensor and its thermal response during irradiations. The aim of this paper is to present simulations made by using MCNP5 Monte-Carlo transport code (using ENDF/B-VI nuclear data library) for the nuclear heating inside the different parts of the calorimeter (head, rod and base). Calculations into two steps will be realized. We will use as an input source in the model new spectra (neutrons, prompt-photons and delayed-photons) calculated with the Monte Carlo code TRIPOLI-4{sup R} inside different experimental channels (water) located into the OSIRIS periphery and used during the CARMEN-1P irradiation campaign. We will consider Neutrons- Photons-Electrons and Photons-Electrons modes. We will begin by a brief description of the differential-calorimeter device geometry. Then the MCNP5 model used for the calculations of nuclear heating inside the calorimeter elements will be introduced. The energy deposition due to the prompt-gamma, delayed-gamma and neutrons, the neutron-activation of the device will be considered. The different components of the nuclear heating inside the different parts of the calorimeter will be detailed. Moreover, a comparison between KERMA and nuclear energy deposition estimations will be given. Finally, a comparison between this total nuclear heating Calculation and Experiment in graphite sample will be determined. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Corrosion of Structural Materials for Advanced Supercritical Carbon- Dioxide Brayton Cycle

The supercritical carbon-dioxide (referred to as SC-CO 2 hereon) Brayton cycle is being considered for power conversion systems for a number of nuclear reactor concepts, including the sodium fast reactor (SFR), fluoride saltcooled high temperature reactor (FHR), and high temperature gas reactor (HTGR), and several types of small modular reactors (SMR). The SC-CO 2 direct cycle gas fast reactor has also been recently proposed. The SC-CO 2 Brayton cycle (discussed in Chapter 1) provides higher efficiencies compared to the Rankine steam cycle due to less compression work stemming from higher SC-CO 2 densities, and allows for smaller components size, fewer components, and simpler cycle layout. For example, in the case of a SFR using a SC-CO 2 Brayton cycle instead of a steam cycle would also eliminate the possibility of sodium-water interactions. The SC-CO 2 cycle has a higher efficiency than the helium Brayton cycle, with the additional advantage of being able to operate at lower temperatures and higher pressures. In general, the SC-CO 2 Brayton cycle is well-suited for any type of nuclear reactor (including SMR) with core outlet temperature above ~ 500°C in either direct or indirect versions. In all the above applications, materials corrosion in high temperature SC-CO 2 is an important consideration, given their expected lifetimes of 20 years or longer. Our discussions with National Laboratories and private industry early on in this project indicated materials corrosion to be one of the significant gaps in the implementation of SC-CO 2 Brayton cycle. Corrosion can lead to a loss of effective load-bearing wall thickness of a component and can potentially lead to the generation of oxide particulate debris which can lead to three-body wear in turbomachinery components. Another environmental degradation effect that is rather unique to CO 2 environment is the possibility for simultaneous occurrence of carburization during oxidation of the material. Carburization can potentially lead to embrittlement of structural alloys in SC-CO 2 Brayton cycle. An important consideration in regards to corrosion is that the temperatures can vary widely across the various sections of the SC-CO 2 Brayton cycle, from room temperature to 750°C, with even higher temperatures being desirable for higher efficiencies. Thus the extent of corrosion and corrosion mechanisms in various components and SC-CO 2 Brayton cycle will be different, requiring a judicious selection of materials for different sections of the cycle. The goal of this project was to address materials corrosion-related challenges, identify appropriate materials, and advance the body of scientific knowledge in the area of high temperature SC-CO 2 corrosion. The focus was on corrosion of materials in SC-CO 2 environment in the temperature range of 450°C to 750°C at a pressure of 2900 psi for exposure duration for up to 1000 hours. The Table below lists the materials tested in the project. The materials were selected based on their high temperature strength, their code certification status, commercial availabilities, and their prior or current usage in the nuclear reactor industry. Additionally, pure Fe, Fe-12%Cr, and Ni-22%Cr were investigated as simple model materials to more clearly understand corrosion mechanisms. This first phase of the project involved testing in research grade SC-CO 2 (99.999% purity). Specially designed autoclaves with high fidelity temperature, pressure, and flow control capabilities were built or modified for this project.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Advanced Instrumentation for Transient Reactor Testing

Transient testing involves placing fuel or material into the core of specialized materials test reactors that are capable of simulating a range of design basis accidents, including reactivity insertion accidents, that require the reactor produce short bursts of intense highpower neutron flux and gamma radiation. Testing fuel behavior in a prototypic neutron environment under high-power, accident-simulation conditions is a key step in licensing nuclear fuels for use in existing and future nuclear power plants. Transient testing of nuclear fuels is needed to develop and prove the safety basis for advanced reactors and fuels. In addition, modern fuel development and design increasingly relies on modeling and simulation efforts that must be informed and validated using specially designed material performance separate effects studies. These studies will require experimental facilities that are able to support variable scale, highly instrumented tests providing data that have appropriate spatial and temporal resolution. Finally, there are efforts now underway to develop advanced light water reactor (LWR) fuels with enhanced performance and accident tolerance. These advanced reactor designs will also require new fuel types. These new fuels need to be tested in a controlled environment in order to learn how they respond to accident conditions. For these applications, transient reactor testing is needed to help design fuels with improved performance. In order to maximize the value of transient testing, there is a need for in-situ transient realtime imaging technology (e.g., the neutron detection and imaging system like the hodoscope) to see fuel motion during rapid transient excursions with a higher degree of spatial and temporal resolution and accuracy. There also exists a need for new small, compact local sensors and instrumentation that are capable of collecting data during transients (e.g., local displacements, temperatures, thermal conductivity, neutron flux, etc.).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1989

Oxygen electrodes for rechargeable alkaline fuel cells

Electrocatalysts and supports for the positive electrode of moderate temperature single-unit rechargeable alkaline fuel cells are being investigated and developed. Candidate support materials were drawn from transition metal carbides, borides, nitrides and oxides which have high conductivity (greater than 1 ohm/cm). Candidate catalyst materials were selected largely from metal oxides of the form ABO sub x (where A = Pb, Cd, Mn, Ti, Zr, La, Sr, Na, and B = Pt, Pd, Ir, Ru, Ni (Co) which were investigated and/or developed for one function only, O2 reduction or O2 evolution. The electrical conductivity requirement for catalysts may be lower, especially if integrated with a higher conductivity support. All candidate materials of acceptable conductivity are subjected to corrosion testing. Materials that survive chemical testing are examined for electrochemical corrosion activity. For more stringent corrosion testing, and for further evaluation of electrocatalysts (which generally show significant O2 evolution at at 1.4 V), samples are held at 1.6 V or 0.6 V for about 100 hours. The surviving materials are then physically and chemically analyzed for signs of degradation. To evaluate the bifunctional oxygen activity of candidate catalysts, Teflon-bonded electrodes are fabricated and tested in a floating electrode configuration. Many of the experimental materials being studied have required development of a customized electrode fabrication procedure. In advanced development, the goal is to reduce the polarization to about 300 to 350 mV. Approximately six support materials and five catalyst materials were identified to date for further development. The test results will be described.

Swette, L.↗