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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 NTRS2004

Lightweight, Low-CTE Tubes Made From Biaxially Oriented LCPs

Tubes made from biaxially oriented liquid-crystal polymers (LCPs) have been developed for use as penetrations on cryogenic tanks. ( Penetrations in this context denotes feed lines, vent lines, and sensor tubes, all of which contribute to the undesired conduction of heat into the tanks.) In comparison with corresponding prior cryogenic-tank penetrations made from stainless steels and nickel alloys, the LCP penetrations offer advantages of less weight and less thermal conduction. An additional major advantage of LCP components is that one can tailor their coefficients of thermal expansion (CTEs). The estimated cost of continuous production of LCP tubes of typical sizes is about $1.27/ft ($4.17/m) [based on 1998 prices]. LCP tubes that are compatible with liquid oxygen and that feature tailored biaxial molecular orientation and quasi-isotropic properties (including quasi-isotropic CTE) have been fabricated by a combination of proprietary and patented techniques that involve the use of counterrotating dies (CRDs). Tailoring of the angle of molecular orientation is what makes it possible to tailor the CTE over a wide range to match the CTEs of adjacent penetrations of other tank components; this, in turn, makes it possible to minimize differential-thermal expansion stresses that arise during thermal cycling. The fabrication of biaxially oriented LCP tubes by use of CRDs is not new in itself. The novelty of the present development lies in tailoring the orientations and thus the CTEs and other mechanical properties of the LCPs for the intended cryogenic applications and in modifications of the CRDs for this purpose. The LCP tubes and the 304-stainless-steel tubes that the LCP tubes were intended to supplant were tested with respect to burst strength, permeability, thermal conductivity, and CTE.

Rubin, Leslie↗
DOE OSTI2022

Effect of solution concentration on ethylene propylene diene monomer (EPDM) nonmetallic components used in caustic liquid waste transfer lines

The hose-in-hose transfer lines (HIHTL) used to transfer waste at the United States Department of Energy’s Hanford Site Tank Farm are fabricated from an ethylene propylene diene monomer (EPDM) synthetic rubber. During waste transport, these hoses are exposed to several stressors including caustic solutions at high temperatures and high pressures, as well as β and γ radiation. The aging behavior of HIHTL and dog-bone shaped EPDM specimens were evaluated by exposure to solutions at 77 °C containing 0.00, 6.25, 12.50, and 25.00 % (v/v) sodium hydroxide (NaOH) for 12-months. After the exposure, the material properties of the specimens were measured and compared to the unaged samples. The material properties evaluated included the tensile strength of the EPDM dog-bone samples and the burst pressure of the HIHTL. Both the tensile strength of the EPDM dog-bone samples and the burst pressure of the HIHTL specimens exposed to the 6.25 % NaOH solution exhibited the most significant deterioration and those exposed to 25.00 % NaOH solution had the least deterioration. Finally, examination of the HIHTL and the EPDM dog-bone specimens with scanning electron microscopy showed that the deterioration for the specimens exposed to 6.25 % NaOH solution were the most severe and the samples exposed to 25.00 % NaOH solution had the least deterioration.

42 ENGINEERING↗
NASA NTRS2009

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Thesken, John C.↗
NASA NTRS2006

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Greene, N.↗
DOE OSTI2025

Performance Comparisons for Artificially Propagated and Wild Pacific Lamprey Juveniles and Larvae

ABSTRACT Artificially propagated Pacific lamprey ( Entosphenus tridentatus ) are produced for restoration and for use in dam passage studies to reduce the demand for wild fish. Such uses require that animals are representative of their wild counterparts. Previous work indicated that this is true for Pacific lamprey larvae and juveniles reared in the hatchery with respect to the length of sustained swimming. However, more subtle differences in behaviour and performance that lamprey need to survive have not been assessed. In this study, artificially propagated and wild fish were compared in laboratory tests under no‐flow conditions to examine light avoidance, burrowing speed, burst swim speed, volitional routine swim speed and time to come to rest. Most larvae burrowed in less than a minute, and we found highly significant differences ( p < 0.001) between artificially propagated and wild larvae burrowing times, a critical escape behaviour. This could have implications for studies of larval entrainment at irrigation diversion canals or in turbine boils at dams. Interestingly, all of the wild juveniles tested came to rest quickly after introduction to the chamber (1.5 min), while artificially propagated lamprey swam robotically near the surface and 48% did not come to rest in the first 10 min (median time to rest = 9.5 min). In contrast, wild juveniles quickly (median = 1.47 min) sought areas near the tank bottom and attached strongly with their oral disc. Such behavioural differences could have important survival consequences for artificially propagated lamprey as they approach turbine intakes, bypass screens and irrigation diversion headgates. This study highlights the need to conduct behavioural assays that examine subtleties of fish behaviour that can be missed with traditional swim tunnel comparisons.

Frick, Kinsey [Fish Ecology Division, Northwest Fi↗
NASA NTRS2008

Method for Thermal Spraying of Coatings Using Resonant-Pulsed Combustion

A method has been devised for high-volume, high-velocity surface deposition of protective metallic coatings on otherwise vulnerable surfaces. Thermal spraying is used whereby the material to be deposited is heated to the melting point by passing through a flame. Rather than the usual method of deposition from the jet formed from the combustion products, this innovation uses non-steady combustion (i.e. high-frequency, periodic, confined bursts), which generates not only higher temperatures and heat transfer rates, but exceedingly high impingement velocities an order of magnitude higher than conventional thermal systems. Higher impingement rates make for better adhesion. The high heat transfer rates developed here allow the deposition material to be introduced, not as an expensive powder with high surface-area-to-volume, but in convenient rod form, which is also easier and simpler to feed into the system. The nonsteady, resonant combustion process is self-aspirating and requires no external actuation or control and no high-pressure supply of fuel or air. The innovation has been demonstrated using a commercially available resonant combustor shown in the figure. Fuel is naturally aspirated from the tank through the lower Tygon tube and into the pulsejet. Air for starting is ported through the upper Tygon tube line. Once operation commences, this air is no longer needed as additional air is naturally aspirated through the inlet. A spark plug on the device is needed for starting, but the process carries on automatically as the operational device is resonant and reignites itself with each 220-Hz pulse.

Paxson, Daniel E.↗
DOE OSTI2020

Accelerated Aging and Evaluation of Hose-In-Hose Transfer Lines in the Hanford Waste Transfer System - 20312

Nonmetallic materials are used in the United States Department of Energy's Hanford Site Tank Farm waste transfer system. These materials include the inner primary hoses in the hose-in-hose transfer lines (HIHTLs), Garlock{sup R} gaskets, ethylene propylene diene monomer (EPDM) O-rings, and other nonmetallic materials. These nonmetallic materials are exposed to β and γ radiation, caustic solutions as well as high temperature and pressure stressors. How the nonmetallic components react to each of these stressors individually has been well established. However, simultaneous exposure of these stressors has not been evaluated and is of great concern to Hanford Site engineers. Florida International University's Applied Research Center engineers worked closely with key Hanford's Washington River Protection Solutions personnel to develop an experimental test plan that determines how these nonmetallic components react to various simultaneous stressor exposures. In this paper, research on the experimental testing of the hose-in-hose transfer lines used in the Hanford tank farm waste transfer system under simultaneous stressor exposures is presented. The stressor exposure experiments consisted of various combinations of simultaneous stressor exposure of caustic solution, high temperature and high pressure stressors. Research efforts focused on evaluating the aging behavior of EPDM by exposing samples of HIHTLs as well as EPDM dog bone shaped specimens to a 25% NaOH solution at (38 deg. C), operating (54 deg. C) and design temperatures (77 deg. C) for 6 months and 12 months. In addition, HIHTL and the EPDM dog-bone specimens were exposed to only hot water at 77 deg. C for a duration of one year. The mechanical and material properties of the samples were characterized and compared with those of the unexposed samples (baseline). Evaluations included burst pressure tests of the EPDM hose-in-hose transfer lines and material tensile strength test of EPDM dog-bone coupons. Both the tensile strength of the EPDM material dog bones and the burst pressure of the HIHTLs significantly decreased with the increasing temperature and increasing exposure time. When compared with the baseline samples, the burst pressure decreased by 28.75% for the sample aged at 77 deg. C after 12 months, in comparison to sample aged at 38 deg. C and 54 deg. C which had about 1.34% and 5.70% loss in burst pressures, respectively, after 12-month exposure. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2013

Self-Healing Nanocomposites for Reusable Composite Cryotanks

Composite cryotanks, or composite overwrapped pressure vessels (COPVs), offer advantages over currently used aluminum-lithium cryotanks, particularly with respect to weight savings. Future NASA missions are expected to use COPVs in spaceflight propellant tanks to store fuels, oxidizers, and other liquids for launch and space exploration vehicles. However, reliability, reparability, and reusability of the COPVs are still being addressed, especially in cryogenic temperature applications; this has limited the adoption of COPVs in reusable vehicle designs. The major problem with composites is the inherent brittleness of the epoxy matrix, which is prone to microcrack formation, either from exposure to cryogenic conditions or from impact from different sources. If not prevented, the microcracks increase gas permeation and leakage. Accordingly, materials innovations are needed to mitigate microcrack damage, and prevent damage in the first place, in composite cryotanks. The self-healing technology being developed is capable of healing the microcracks through the use of a novel engineered nanocomposite, where a uniquely designed nanoparticle additive is incorporated into the epoxy matrix. In particular, this results in an enhancement in the burst pressure after cryogenic cycling of the nanocomposite COPVs, relative to the control COPVs. Incorporating a novel, self-healing, epoxy-based resin into the manufacture of COPVs allows repeatable self-healing of microcracks to be performed through the simple application of a low-temperature heat source. This permits COPVs to be reparable and reusable with a high degree of reliability, as microcracks will be remediated. The unique phase-separated morphology that was imparted during COPV manufacture allows for multiple self-healing cycles. Unlike single-target approaches where one material property is often improved at the expense of another, robustness has been introduced to a COPV by a combination of a modified resin and nanoparticle additives. Unique nanoparticles were used that have been surface-functionalized to be compatible with the resin. Both organic and inorganic components toughen the matrix and result in a more impact-resistant COPV. In one resin system containing an inorganic nanomaterial additive, a significant improvement in burst performance was observed after the COPV was cryo-impact-damaged and then self-healed, with a greater than 10% improvement in burst pressure after the self-healing process was performed. Initial cross-sectional analysis via microscopy showed good resin infiltration of the carbon fibers and without voids. To further enhance the capability between the nanomaterial additives and the resin, a surface modification was successfully performed. A second specialty epoxy resin was prepared using a surface modified nanomaterial additive, and COPVs were fabricated. Steps were taken to improve the mechanical properties of the COPVs by using a low-viscosity resin system that contained a different curing agent. This lower viscosity improves the processing of the COPV, and preliminary results show that the burst pressure of these new vessels is 20 to 25% higher than that of the original. The self-healing concept demonstrated in this research and development effort represents a platform technology, and the self-healing property is neither restricted to the particular epoxy system used here, nor to the COPV application. Self-healing is a direct result of a unique phase separated morphology created via the resin and is aided by the nanoparticles. The self-healing function can be introduced to other customer-specific resin systems in coating, bulk, or composite applications provided that the unique phase separated morphology can be enabled in those systems.

Eberly, Daniel↗
NASA NTRS2004

Freeze Tolerant Radiator for an Advanced EMU

During an Extravehicular Activity (EVA), the astronaut s metabolic heat and the heat produced by the Portable Life Support Unit (PLSS) must be rejected. This heat load is currently rejected by a sublimator, which vents up to eight pounds of water each EVA. However, for advanced space missions of the future, water venting to space needs to be minimized because resupply impacts from earth will be prohibitive. If this heat load could be radiated to space from the PLSS, which has enough surface area to radiate most of the heat, the amount of water now vented could be greatly reduced. Unfortunately, a radiator rejects heat at a relatively constant rate, but the astronauts generate a variable heat load depending on how hard they are working. Without a way to vary the heat removal rate, the astronaut would experience cold discomfort or even frostbite. A proven method allowing a radiator to be turned-down is to sequentially allow tubes that carry the heat transfer fluid to the radiator to freeze. A drawback of current freezable radiators using this method is that they are far to heavy for use on a PLSS, because they use heavy construction to prevent the tubes from bursting as they freeze and thaw. This creates the need for a large radiator to reject most of the heat but with a lightweight tube that doesn t burst as it freezes and thaws. The new freezable radiator for the Extravehicular Mobility Unit (EMU) has features to accommodate the expansion of the radiator fluid when it freezes, and still have the high tube to fin conductance needed to minimize the number and weight of the tubes. Radiator fluid candidates are water and a propylene glycol-water mixture. This design maintains all materials within their elastic limits so that large volume changes can be achieved without breaking the tube. This concept couples this elastic expansion with an extremely lightweight, extremely high conductivity carbon fiber fin that can carry the heat needed to thaw a frozen tube. By using most of the exposed surface area of the PLSS as a radiator, the system can reject about 75% of the highest heat load, and reduce the loss of water through sublimation by a factor of four. The proposed radiator and a small water tank can be no heavier than the current system.

Copeland, Robert J.↗
NASA NTRS2009

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifting Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle s Kevlar-49 (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed nonconservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23 percent lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
NASA NTRS2011

Composite Overwrapped Pressure Vessels (COPV): Flight Rationale for the Space Shuttle Program

Each Orbiter Vehicle (Space Shuttle Program) contains up to 24 Kevlar49/Epoxy Composite Overwrapped Pressure Vessels (COPV) for storage of pressurized gases. In the wake of the Columbia accident and the ensuing Return To Flight (RTF) activities, Orbiter engineers reexamined COPV flight certification. The original COPV design calculations were updated to include recently declassified Kevlar COPV test data from Lawrence Livermore National Laboratory (LLNL) and to incorporate changes in how the Space Shuttle was operated as opposed to orinigially envisioned. 2005 estimates for the probability of a catastrophic failure over the life of the program (from STS-1 through STS-107) were one-in-five. To address this unacceptable risk, the Orbiter Project Office (OPO) initiated a comprehensive investigation to understand and mitigate this risk. First, the team considered and eventually deemed unfeasible procuring and replacing all existing flight COPVs. OPO replaced the two vessels with the highest risk with existing flight spare units. Second, OPO instituted operational improvements in ground procedures to signficiantly reduce risk, without adversely affecting Shuttle capability. Third, OPO developed a comprehensive model to quantify the likelihood of occurrance. A fully-instrumented burst test (recording a lower burst pressure than expected) on a flight-certified vessel provided critical understanding of the behavior of Orbiter COPVs. A more accurate model was based on a newly-compiled comprehensive database of Kevlar data from LLNL and elsewhere. Considering hardware changes, operational improvements and reliability model refinements, the mean reliability was determined to be 0.998 for the remainder of the Shuttle Program (from 2007, for STS- 118 thru STS-135). Since limited hardware resources precluded full model validation through multiple tests, additional model confidence was sought through the first-ever Accelerated Stress Rupture Test (ASRT) of a flown flight article. A Bayesian statistical approach was developed to interpret possible test results. Since the lifetime observed in the ASRT exceeded initial estimates by one to two orders of magnitude, the Space Shuttle Program deemed there was significant conservatism in the model and accepted continued operation with existing flight hardware. Given the variability in tank-to-tank original prooftest response, a non-destructive evaluation (NDE) technique utilizing Raman Spectroscopy was developed to directly measure COPV residual stress state. Preliminary results showed that patterns of low fiber elastic strains over the outside vessel surface, together with measured permanent volume growth during proof, could be directly correlated to increased fiber stress ratios on the inside fibers adjacent to the liner, and thus reduced reliability.

Kezirian, Michael T.↗
NASA NTRS2007

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifing Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle's Kevlar-49 fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed non-conservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic-plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23% lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
NASA NTRS2026

Polymer Composite Material Testing for a Cryotank Application

Composite cryotanks will play a key role in enabling the next generation of efficient aircraft. Carbon fiber reinforced polymer (CFRP) composites have the benefits of reduced weight and potentially higher structural strength compared to traditional metallic fuel tanks. A material screening study was conducted to inform material selection for liquid hydrogen (LH2) fuel storage. Three composite materials were considered because of their aerospace grade toughness, strength, and existing data to compare against. These materials were a thermoplastic low-melt polyaryletherketone (LM-PAEK)/carbon fiber (CF), thermoset/CF, and hybrid thermoset/thermoplastic polyurethane (TPU) veil/CF composite. Mechanical screening tests included tension, compression, in-plane shear (IPS), and tensile-tensile fatigue (TTF). Each material was tested at both a baseline (no liquid nitrogen/LN2 cycling) and 100 LN2-cycled conditions to determine the knockdown factor, if any, of each material when exposed to environmental loading effects in a cryotank. Results show minimal effects of the LN2-cycling compared against baseline values. The three materials behaved similarly in tension; however, the thermoplastic/CF had the highest IPS toughness. The hybrid thermoset/TPU/CF composite had the lowest IPS strength, compressive strength, and toughness. LN2-cycling had minimal effects on tensile-tensile fatigue performance of the thermoplastic/CF material. Mechanical data was captured to guide material down selection for future commercially viable hydrogen aircraft design. In its current state, there does not exist a consolidated, publicly available database for CFRP composite material performance data at cryogenic temperatures. The next step in this work is to test the thermoplastic and thermoset CFRP composites, as well as the neat resins, at LH2 relevant temperature (20 K) to capture this crucial material property data. These results are essential to inform cryotank design and modeling efforts. The process to start this next round of testing has begun. Planned mechanical tests include toughness (single-edge notched beam), tension (unidirectional and quasi-isotropic), thermal expansion, and thermal conductivity. Some tests will also be conducted at an intermediate temperature of 111 K relevant to liquid natural gas (LNG), another attractive fuel choice. The ultimate goal is to manufacture a sub-scale cryotank part that can pass relevant burst, fatigue, permeation, and thermal cycling tests. This work is a part of NASA’s Commercially viable Hydrogen Aircraft for Robust Growth in Efficiency (CHARGE) Project under the larger NASA Subsonic Vehicle Technologies and Tools (SVTT) Project.

composites↗
DOE OSTI2025

Modeling and Simulation of Fuel Dispersal During the Loss-of-Coolant Accident

This document is the compilation of the milestone portion to a larger end of project NEUP report. The executive summary of the modeling portion is provided below: In the event of cladding rupture during a postulated LOCA in a pressurized water reactor, fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod, a phenomenon referred to as fuel dispersal. The initial stage of fuel dispersal is strongly influenced by the high-pressure ejection of fuel fragments, the size and geometry of the ruptured cladding, and the depressurization history of the fuel rod during the postulated LOCA transient. Depending on the location of the burst orifice relative to the quench front, the dispersal event represents an intricate three-phase flow and heat transfer phenomenon, where high-temperature fuel particles carried by the fission gases interact with the coolant within the narrow subchannels of the fuel assemblies, inducing localized phase change. Given the unique multiphysics nature of this phenomena, the current study develops a dedicated computational framework to predict the mass distribution and cooling of dispersing fuel particles, facilitating post-accident assessment and management of the fuel assemblies. Considering the scale of nuclear reactor applications, a continuum three-fluid model is proposed for simulating the transport of solids within the reactor core. With high-temperature fuel fragments within the liquid media, nucleation sites inducing phase changes are dispersed within the flow domain. Coupled with the fact that the transient dispersal event occurs on different time scales than other three-phase flow applications, this study derives a time-averaged three-fluid flow model without losing generality. The assumptions regarding the continuum treatment of the solid phase and the modeling of fuel dispersal behavior are incorporated to simplify the governing equations and derive applicable closure relations. The computational validation of the model was conducted using adiabatic experimental results obtained from ongoing research at Oregon State University, focusing on characterizing fuel dispersal behavior during simulated LOCA conditions. Settlement characteristics of the solids, quantified by the probability distribution of equivalent particles, closely matched the probability density functions reported in experimental studies. The transport of fuel particles within a scaled 5 × 5 lattice of a pressurized-water reactor rod bundle geometry was modeled through a two-fluid Eulerian framework. The required boundary conditions were evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considered solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum exchange between the participating fluids. The simulation results provided the volume fraction of the solids obtained at the bottom surface of the enclosing tank geometry. Postulated LOCA leading to fuel dispersal phenomena involves the strong coupling between fuel thermomechanics, cladding deformation, thermal-hydraulics, and fuel particle transport. Incorporation of such a strong coupling in numerical simulation is performed by coupling the multiphysics solvers. In the case of fuel dispersal, a strong coupled simulation can be performed by coupling the BISON code for fuel performance, the TRACE code for system-level thermal hydraulics, and fuel particle transport in Multiphysics Object-Oriented Simulation Environment (MOOSE). For such intricate infrastructure, the MOOSE Framework eases the data transfer between codes. The recent version of MOOSE has incorporated the Navier-Stokes module for the fluid flow. An exploratory exercise was done to gain familiarity with finite volume capabilities in the MOOSE framework to incorporate the Spalart-Allmaras (SA) turbulence model. New finite-volume and auxiliary kernels were introduced to assemble the SA transport equation, compute turbulent viscosity, and evaluate wall distance and diagnostic turbulence terms, fully integrated with existing Navier-Stokes modules. A turbulent lid-driven cavity at a Reynolds number of approximately 10,000 is used for verification. MOOSE shows the robust solver convergence and produces the turbulent features. But it underpredicts the velocity profile and turbulent quantities, emphasizing the need to develop improved SA near-wall treatments (e.g., low-Re corrections or wall functions) as a key direction for future work.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗