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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3

Surface fatigue and failure characteristics of hot-forged powder metal AISI 4620, AISI 4640, and machined AISI 4340 steel spur gears

Spur gear surface fatigue endurance tests were conducted to investigate hot forged powder metal AISI 4620 and 4640 steel for use as a gear material, to determine endurance characteristics and to compare the results with machined AISI 4340 and 9310 steel gear materials. The as-forged and unground AISI 4620 gear exhibited a 10 percent fatigue life that was approximately one-fourth of that for AISI 9310 and less than one-half that for the AISI 4340 gears. The forged and finish ground AISI 4620 gears exhibited a 10 percent life, approximately 70 percent that of AISI 9310 and slightly better than that of AISI 4340. The AISI 4640 hot forged gears had less fracture toughness and slightly less fatigue life than the AISI 4620 test gears.

Townsend, Dennis P.↗

Shock Hugoniot of forged and additively manufactured 304L stainless steel

The purpose of this research was to measure the equation of state for additively manufactured (AM) and forged 304L stainless steel. An understanding of the dynamic behavior of AM metals is integral to their timely adoption into industrial and governmental applications. The Hugoniot of the AM 304L was compared to that of the forged 304L. This comparison enabled us to determine the sensitivity of the equation of state to processing parameters and the resulting microstructure. Our results show that there is a measurable difference in the Hugoniot between the AM 304L and forged 304L. The shock wave velocities for the AM 304L were found to be slower than those for the forged 304L at similar particle speeds perhaps because of the presence of porosity in the AM 304L. While our measurements of density showed no distinct trend toward a measurable decrease in density in the AM 304L, there was a fair amount of scatter in these results.

36 MATERIALS SCIENCE↗

Utah FORGE: Well 16A(78)-32 Planned Trajectory

This submission includes an Excel spreadsheet containing the Utah FORGE deep well 16A(78)-32 planned trajectory including UTM coordinates, elevations, and depths from the well head to the toe. This proposed new injection well is expected to descend vertically to a depth of approximately 1810 m and then extend laterally at an angle to a MD of approximately 3290 m and a maximum vertical depth of approximately 2584 m. There is approximately 1500 m of basin fill at the well head, and less than that above the simulation region with the targeted reservoir region fully enclosed in granitoid basement. The last 60 m of the well will be open hole. Drilling is planned for October 2020. Please direct questions to the Utah FORGE team: utahforge@utah.edu and check the Utah FORGE website: https://utahforge.com after October for more information.

15 GEOTHERMAL ENERGY↗

Utah FORGE: Phase 3 Ground Water Level Monitoring Data

Groundwater data around the Utah FORGE site has been collected to determine the piezometric levels and compositional variability. Field measurements in 2020 are designed to obtain and survey new groundwater wells that have been drilled on the distal periphery of the Utah FORGE project area. The spreadsheet included in this submission contains ground water level data from the Utah FORGE site as monitored from wells WOW-2 and WOW-3. The well locations are also provided as UTM, Zone 12, NAD83 coordinates.

15 GEOTHERMAL ENERGY↗

Utah FORGE Well 16A(78)-32 Simplified Discrete Fracture Network Data

The FORGE team is making these fracture models available to researchers wanting a set of natural fractures in the FORGE reservoir for use in their own modeling work. They have been used to predict stimulation distances during hydraulic stimulation at the open toe section of well 16A(78)-32. This is a simplified DFN (discrete fracture network) dataset, that was generated using FracMan, for Utah FORGE well 16A(78)-32. A short, well-illustrated, report describing the data is also included in the provided archive file.

15 GEOTHERMAL ENERGY↗

Utah FORGE 2439: A Multi-Component Approach to Characterizing In-Situ Stress

Core-based in-situ stress estimation, Triaxial Ultrasonic Velocity (labTUV) data, and Deformation Rate Analysis (DRA) data for Utah FORGE well 16A(78)-32 using triaxial ultrasonic velocity and deformation rate analysis. Report documenting a multi-component approach to characterizing in-situ stress at the U.S. DOE FORGE EGS site: laboratory, modeling and field measurement. Core-based methods for in-situ stress estimation were applied using samples from 5 intervals within the Utah FORGE 16A(78)-32 well. At three of these locations, Triaxial Ultrasonic Velocity (labTUV) tests were performed, resulting in experimentally-determined relationships between wave velocities and stresses. Non-monotonic increase in the velocity-stress relationships are inferred provide evidence of stress history and are therefore used to estimate in-situ stress magnitudes. Additionally, Deformation Rate Analysis (DRA) tests were run on core plugs from various orientations at each of the 5 sampling locations. These, too, provide evidence of stress history based on stress-strain behavior. A novel Weight of Evidence (WoE) method was developed as a means of synthesizing in-situ stress evidence from these two types of tests. Results indicate the minimum horizontal stress gradient ranges from 0.58 psi/ft to 0.69 psi/ft, with 4 of the 5 values between 0.66 psi/ft and 0.69 psi/ft. The vertical stress gradient ranges from 1.05 psi/ft to 1.12 psi/ft, with 4 of the 5 zones given results between 1.09 psi/ft and 1.12 psi/ft. The maximum horizontal stress gradient ranges from 0.98 psi/ft to 1.34 psi/ft, with 4 of the 5 zones falling between 0.98 psi/ft and 1.24 psi/ft. The stress regime thus appears to be on the edge between normal faulting and strike-slip faulting, potentially flipping back and forth between the two regimes due to variability of rock properties, structures such as faults, and/or thermal anomalies.

15 GEOTHERMAL ENERGY↗

Effect of cold forging on the microstructure and corrosion behavior of type 316L stainless steel in molten FLiNaK salt

Here, the effect of cold forging on the microstructure and corrosion behavior of 316L stainless steel (SS) in molten salt was investigated. Static corrosion experiments were performed in FLiNaK (LiF-NaF-KF: 46.5–11.5–42 mol.%) at 600 °C for 50 h in a glove box. The results show that cold forging gives rise to enhanced corrosion of 316L SS in molten fluoride salt due to the increase of crystallographic defects. Based on the potentiodynamic polarization results, the corrosion current density of 50 % cold-forged 316L SS is about 2.1 times larger than that of the as-received 316L SS in molten FLiNaK salt at 600 °C.

316L stainless steel↗

Utah FORGE: Optimization of a Plug-and-Perf Stimulation (Fervo Energy)

Information around the plug-and-perf treatment design at Utah FORGE by Fervo Energy. Objective and Purpose: - Develop a multistage hydraulic stimulation approach designed specifically to target the top three factors that control the technical and commercial viability of an EGS system: i) Achieving sufficient injectivity to support high cross-well flow rates ii) Distributing flow evenly across the wellbore and reservoir to maximize heat mining efficiency, ensure sustained heat transfer, and mitigate thermal breakthrough iii) Overcoming the effects of stress heterogeneity, stress shadowing, and variations in natural fracture properties during the stimulation treatment, leading to a more predictable stimulated reservoir volume and offset well placement - The following activities will be performed: i) Design, plan, and execute a multistage plug-and-perf stimulation treatment at a Fervo site with data acquisition and well testing activities aimed at addressing key technical aspects of the issues above ii) Perform data processing and interpretation of field results to translate the results form the Fervo site to a site-specific design at the Utah FORGE site iii) Design, plan, and execute a multistage plug-and-perf stimulation treatment design at the Utah FORGE site Methods and Approach: - Design a detailed data acquisition plan to maximize learning around: i) DFIT testing ii) Petrophysical logging, image logging iii) Permanent DAS/DTS fiber optic monitoring iv) Deep borehole microseismic monitoring v) Shallow borehole induced seismicity monitoring vi) Injection/production testing (RTA analysis, tracer testing) vii) Integrated numerical modeling and production forecasting

15 GEOTHERMAL ENERGY↗

Utah FORGE 2-2439: A Multi-Component Approach to Characterizing In-Situ Stress: Laboratory, Modeling and Field Measurement - Workshop Presentation

This is a presentation on A Multi-Component Approach to Characterizing In-Situ Stress at the U.S DOE FORGE EGS Site: Laboratory, Modeling and Field Measurement project by Battelle [Columbus, OH], presented by Mark Kelley. The project's objective was to characterize stress in the Utah FORGE EGS reservoir using three methods: a laboratory rock-core stress estimation combined with a Machine Learning approach for estimation of in-situ stress from field sonic-log data, a field based in-situ measurement (min-frac) approach, and a modeling approach. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 7, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development of Enhanced Geothermal Systems (EGS) reservoirs and resources.

15 GEOTHERMAL ENERGY↗

Utah FORGE 2-2439v2: Characterizing In-Situ Stress with Laboratory Modelling and Field Measurements - 2024 Annual Workshop Presentation

This is a presentation on A Multi-Component Approach to Characterizing In-Situ Stress at the Utah FORGE Site: Laboratory Modelling and Field Measurements project by The University of Pittsburgh, presented by Andrew Bunger. The project characterizes the stress in the Utah FORGE EGS reservoir using three methods: Method 1: Demonstrate complimentary laboratory rock-core stress estimation combined with Machine Learning approach for measuring in-situ stress from field sonic log data; Method 2: Complete field based in-situ measurement (mini-frac); and Method 3: Develop a mechanics-based method for connection near wellbore stress measurements to stresses away from the well-bore. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 14, 2024.

15 GEOTHERMAL ENERGY↗

Utah FORGE Composite Raw Gravity Data 2021

This is a composite raw gravity dataset of the Utah FORGE area taken over time from December 2018 to to June 2021. The data shows differences in local gravity at different location across Utah FORGE. Included with the gravity data is the NAD83 UTM coordinates of each station in meters. More detailed information can be found in the readme included in the data resource.

15 GEOTHERMAL ENERGY↗

Utah FORGE Telluric Monitoring Experiment Transfer Functions

The Utah Frontier Observatory for Research in Geothermal Energy (FORGE) attempted a stimulation at well 16A(78)-32 during April and May 2022. We recorded telluric and magnetotelluric (MT) data before, during, and after the well stimulation experiment using the FORGE Telluric Monitoring (FTM) array to constrain transients in the Earth's electrical structure caused by the stimulation.

15 GEOTHERMAL ENERGY↗

Utah FORGE: Updated Phase 2C Well Location Coordinates

Utah FORGE has been established to develop, test, and improve the technologies and techniques required to develop EGS-type geothermal resources. Drilling of the first of two deep deviated wells, 16A(78)-32, will begin in the second half of 2020. This well will serve as the injection well for the injection-production well pair that will form the heart of the laboratory. This submission contains an archive of well location data within the Roosevelt Hot Springs geothermal area. An Excel spreadsheet is included containing updated GPS data for Utah FORGE wells drilled during Phase 2C (56-32, 68-32, 78-32). This data was collected over time by the Utah Geological Survey and contains all coordinates collected and the final averaged XY coordinates in both Longitude and Latitude and UTM Zone 12, NAD83. Elevation is also included. GIS shapefiles with well points are provided in the archive.

15 GEOTHERMAL ENERGY↗

Comparing structure-property evolution for PM-HIP and forged alloy 625 irradiated with neutrons to 1 dpa

The nuclear power industry has growing interest in qualifying powder metallurgy with hot isostatic pressing (PM-HIP) to replace traditional alloy fabrication methods for reactor structural components. But there is little known about the response of PM-HIP alloys to reactor conditions. This study directly compares the response of PM-HIP to forged Ni-base Alloy 625 under neutron irradiation doses ~0.5–1 displacements per atom (dpa) at temperatures ranging ~321–385 °C. Post-irradiation examination involves microstructure characterization, ASTM E8 uniaxial tensile testing, and fractography. Up through 1 dpa, PM-HIP Alloy 625 appears more resistant to irradiation-induced cavity nucleation than its forged counterpart, and consequently experiences significantly less hardening. This observed difference in performance can be explained by the higher initial dislocation density of the forged material, which represents an interstitial-biased sink that leaves a vacancy supersaturation to nucleate cavities. These findings show promise for qualification of PM-HIP Alloy 625 for nuclear applications, although higher dose studies are needed to assess the steady-state irradiated microstructure.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Evaluation of Single-Cell Cavities Made of Forged Ingot Niobium at Jefferson Lab

Currently, fine grain niobium (Nb) (grain size ~ 50 um) and large grain Nb (grain size of a few cm) are being used for the fabrication of superconducting radio frequency (SRF) cavities. Medium grain forged ingot with grain size of a few hundred um may be beneficial for cost-effectiveness as well as providing better performance for future SRF-based accelerators. Forged ingot Nb with medium grain size is a novel production method to obtain Nb discs used for the fabrication of superconducting radio frequency cavities. We have fabricated two 1.5 GHz single cell cavities made from forged Nb ingot with a residual resistivity ratio of ~100. The cavities were chemically and mechanically polished and heat-treated in the temperature range of 650-1000 C before the rf test. One of the cavities reached an accelerating gradient of 34 MV/m with a quality factor Q > 1e10, while the second cavity was limited at 14 MV/m, likely due to a weld defect at the equator.

Dhakal, P.↗

Characterization of large 2219 aluminum alloy hand forgings for the space shuttle solid rocket booster

The mechanical properties, including fracture toughness, and stress corrosion properties of four types of 2219-T852 aluminum alloy hand forgings are presented. Weight of the forgings varied between 450 and 3500 lb at the time of heat treatment and dimensions exceeded the maximum covered in existing specifications. The forgings were destructively tested to develop reliable mechanical property data to replace estimates employed in the design of the Space Shuttle Solid Rocket Booster (SRB) and to establish minimum guaranteed properties for structural refinement and for entry into specification revisions. The report summarizes data required from the forgers and from the SRB Structures contractor.

Brennecke, M. W.↗

High Temperature, Slow Strain Rate Forging of Advanced Disk Alloy ME3

The advanced disk alloy ME3 was designed in the HSR/EPM disk program to have extended durability at 1150 to 1250 F in large disks. This was achieved by designing a disk alloy and process producing balanced monotonic, cyclic, and time-dependent mechanical properties. combined with robust processing and manufacturing characteristics. The resulting baseline alloy, processing, and supersolvus heat treatment produces a uniform, relatively fine mean grain size of about ASTM 7, with as-large-as (ALA) grain size of about ASTM 3. There is a long term need for disks with higher rim temperature capabilities than 1250 F. This would allow higher compressor exit (T3) temperatures and allow the full utilization of advanced combustor and airfoil concepts under development. Several approaches are being studied that modify the processing and chemistry of ME3, to possibly improve high temperature properties. Promising approaches would be applied to subscale material, for screening the resulting mechanical properties at these high temperatures. n obvious path traditionally employed to improve the high temperature and time-dependent capabilities of disk alloys is to coarsen the grain size. A coarser grain size than ASTM 7 could potentially be achieved by varying the forging conditions and supersolvus heat treatment. The objective of this study was to perform forging and heat treatment experiments ("thermomechanical processing experiments") on small compression test specimens of the baseline ME3 composition, to identify a viable forging process allowing significantly coarser grain size targeted at ASTM 3-5, than that of the baseline, ASTM 7.

Gabb, Timothy P.↗

Assessment of NASA Dual Microstructure Heat Treatment Method for Multiple Forging Batch Heat Treatment

NASA dual microstructure heat treatment technology previously demonstrated on single forging heat treat batches of a generic disk shape was successfully demonstrated on a multiple disk batch of a production shape component. A group of four Rolls-Royce Corporation 3rd Stage AE2100 forgings produced from alloy ME209 were successfully dual microstructure heat treated as a single heat treat batch. The forgings responded uniformly as evidenced by part-to-part consistent thermocouple recordings and resultant macrostructures, and from ultrasonic examination. Multiple disk DMHT processing offers a low cost alternative to other published dual microstructure processing techniques.

Gayda, John↗