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DOE OSTI2022

Thermal-Epithermal eXperiments – Hafnium Experiment Performed at the DOE’s National Criticality Experiments Research Center (NCERC)

The Thermal-Epithermal eXperiments (TEX) – Hafnium (TEX-Hf) experiments were completed in October 2022 at the DOE National Criticality Experiments Research Center (NCERC) at the Nevada National Security Site (NNSS). This measurement campaign provides seven unique configurations that can be used to validate the neutron absorption and scattering cross sections of hafnium in a highly enriched uranium (HEU) system. Hafnium is a strong neutron absorber important for marine propulsion systems. Mike Zerkle of the Naval Nuclear Laboratory (NNL) states, “The experiments were requested by Naval Reactors to provide a suite of unclassified, clean, and well-characterized benchmarks to drive improvements to hafnium nuclear data.” The experiments were a collaboration between Los Alamos National Laboratory (LANL), Lawrence Livermore National Laboratory (LLNL), and NNL, funded by the Nuclear Criticality Safety Program (NCSP). The Hf was procured directly by NNL and provided for the experiment.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Alternative Power and Propulsion for Space Systems

What are the main sources of power and propulsion for space systems and what are their advantages, disadvantages, how do they work, and what are the politics behind them? The following topics will be analyzed solar panels, batteries, radioisotope thermoelectric generator (RTG), advanced Stirling radioscopic generator (ASRG), reactors, nuclear thermal rockets (NTP), thermionic experiment with conversion (TOPAZ), electrothermal plasma thruster (VASIMR), ion propulsion, and finally nuclear pulse propulsion. The production of Pu-238 is extremely controversial but a vital source of fuel for many of these space systems. Soral and Batteries are the most common and the least controversial forms of power used in space systems today. However, is ineffective for deep space exploration as they only function for up to four years without needing to be recharged. This is where nuclear systems come into play. Nuclear systems such as an RTG will “live” up to 88 years. For example, Voyager 1 is powered by an RTG It has been traveling since 1977 and has left out solar system in 2012 and has yet to run out of power. However, this type of technology (nuclear) has many hurtles it needs to jump through before advancements in can go much further.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Post-irradiation examination of UN-Mo-W fuels for space nuclear propulsion

The National Aeronautics and Space Administration's return to space nuclear propulsion stems from the need for a more efficient method of space travel. Nuclear thermal propulsion systems have been shown to be two times more efficient than chemical propulsion. NASA's Sirius program was created to fabricate and test fuels for space nuclear propulsion, specifically to determine their performance under prototypical startup conditions. The Sirius project featured 4 test capsules, Sirius-1 featured uranium nitride fuel dispersed in a matrix of tungsten and rhenium, while Sirius-2A, -2B, and -3 featured uranium nitride-molybdenum-tungsten fuel (UN-Mo-W). This study discusses the Sirius-2A and -2B irradiation experiments at the Idaho National Laboratory, specifically their performance under irradiation at the Transient Reactor Test Facility. It was found that the fuel samples overall did not exhibit significant cracking, though the Sirius-2A fuel did have one large crack on the surface of the fuel. There was minimal hydrogen absorption in the samples, though it is unknown if the absorption occurred during irradiation or during fabrication. Mechanical testing indicated that the UN fuel demonstrated ceramic behavior as expected, and the Mo/W matrix demonstrated linear elastic behavior to failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

World’s First Vertical GaN based High Power (200 kW) Multi-level Traction Electric Drive Design

Vertical GaN (vGaN) technology leverages a fully conductive 3D semiconductor structure, enabling superior power density compared to GaN-on-Si and other wide bandgap devices. It offers a pathway to surpass cost and efficiency limitations of Si and SiC devices in traction applications. However, scaling for high-voltage, high-power systems remains challenging. This paper presents the design of an 800V, 200kW traction inverter utilizing vertical GaN devices. The inverter achieves ultra-high efficiency (> 99.5%) through advanced power module integration and employs multilevel neutral-point-less X-type (NPL.X) inverter topology to ensure optimal traction drive system performance. These innovations demonstrate the potential of vGaN for nextgeneration electric propulsion systems.

Alam, Khorshed [General Motors LLC, Detroit, MI (U↗

DOE OSTI2022

Materials properties characterization in the most extreme environments

Abstract There is an ever-increasing need for material systems to operate in the most extreme environments encountered in space exploration, energy production, and propulsion systems. To effectively design materials to reliably operate in extreme environments, we need an array of tools to both sustain lab-scale extreme conditions and then probe the materials properties across a variety of length and time scales. Within this article, we examine the state-of-the-art experimental systems for testing materials under extreme environments and highlight the limitations of these approaches. We focus on three areas: (1) extreme temperatures, (2) extreme mechanical testing, and (3) chemically hostile environments. Within these areas, we identify six opportunities for instrument and technique development that are poised to dramatically impact the further understanding and development of next-generation materials for extreme environments. Graphical abstract

Schreiber, Daniel K.↗

DOE OSTI2023

Effects of non-thermal termolecular reactions on wedge-induced oblique detonation waves

The shock-induced combustion ramjet (Shcramjet) based on oblique detonation waves (ODWs) is among the promising choices for hypersonic propulsion systems. An understanding of the ignition, propagation, and stability of ODWs is critical to harnessing their propulsive potential. In such high speed reacting flows, there is a high probability of occurrence of non-thermal reactions due to the presence of non-trivial amounts of highly reactive radicals including H, O and OH apart from O 2 as demonstrated recently [M. P. Burke, S. J. Klippenstein, Nat. Chem. 9 (2017) 1078–1082, Y. Tao, A. W. Jasper, Y. Georgievskii, S. J. Klippenstein, R. Sivaramakrishnan, Proc. Combust. Inst. 38 (2021) 515–522]. The present work focuses on examining the initiation, propagation and structure of oblique detonation waves in stoichiometric H 2 -air mixtures through numerical simulations with and without non-thermal reactivity on a two-dimensional adaptive grid. Non-thermal reactions were included in the macroscopic kinetic model as chemically termolecular reactions facilitated by the H + OH radical-radical recombination and the H + O 2 radical-molecule association reactions. Since, the non-thermal reactions result in a corresponding decrease in the reaction fluxes of the incipient recombination/association reactions, an additional simulation was performed by applying corrections to the respective incipient recombination/association rate constants using the methodology demonstrated by Tao et al. [Y. Tao, A. W. Jasper, Y. Georgievskii, S. J. Klippenstein, R. Sivaramakrishnan, Proc. Combust. Inst. 38 (2021) 515–522]. Results show that, under ODWE relevant conditions, non-thermal reactivity fundamentally alters the induction length, intensity as well as the structure of the ODW. Specifically, it is found that non-thermal reactivity leads to a noticeable reduction in initiation length and a simultaneous increase in instantaneous peak heat release rate and the degree of unsteadiness of the ODW. Finally, statistical analysis of key thermo-chemical variables is performed to elucidate the important species as well as reactions responsible for the observed variations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Rare Earth Permanent Magnets: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for rare earth permanent magnets, specifically sintered neodymiumiron-boron (NdFeB) magnets, used in clean energy technologies. Sintered NdFeB magnets are the strongest magnets commercially available and provide a host of benefits to wide-ranging applications in consumer and industrial electronics, especially in advanced motor and drive systems. Within the Energy Sector Industrial Base, and clean energy in particular, NdFeB magnets are key intermediate components of permanent magnet synchronous (direct drive) generators in wind turbines (especially for offshore turbines) and electric synchronous traction motors for propulsion systems in battery and hybrid electric vehicles.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Microscopic analysis of irradiated UN–Mo–W for space nuclear propulsion

Nuclear propulsion is an effective method of providing thrust in deep space, allowing for shorter mission duration for long-term surface missions to Mars. The fuel for nuclear propulsion systems must exhibit superior mechanical and thermal properties, to decrease the possibility of fuel failure and to increase reactor efficiency. Here, the objective of the Sirius project is to fabricate and irradiate cermet fuels at the Idaho National Laboratory Transient Reactor Facility to determine the properties of the fuel after irradiation at prototypical nuclear propulsion start-up conditions. The Sirius project featured 3 test capsules, Sirius-1 featured uranium nitride fuel dispersed in a matrix of tungsten and rhenium, while Sirius-2A and -2B featured uranium nitride-molybdenum-tungsten fuel (UN-Mo-W). The fuel samples from the Sirius-2A and -2B capsules were examined after irradiation using optical microscopy, scanning electron microscopy, and X-ray diffraction analyses. The mechanical properties of the fuel from Sirius-2A and -2B are discussed in a previous work. In this study, the results of the optical microscopy, scanning electron microscopy, and X-ray diffraction analyses are discussed.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

System and method for torque split arbitration

A method for torque split arbitration in a vehicle includes identifying at least one route characteristic of a portion of a route being traversed by the vehicle. The method further includes determining a target torque split based on the at least one route characteristics. The method further includes generating a first output torque demand that corresponds to a product of a first portion of a target torque demand to be provided by a first propulsion unit and a ratio of a total propulsion system torque demand and the target torque demand. The method further includes generating a second output torque demand based on the first output torque demand.

Aggoune, Karim↗

DOE OSTI2021

Prototype tests of the electromagnetic particle injector-2 for fast time response disruption mitigation in tokamaks

Predicting and controlling disruptions is an important and urgent issue for ITER. Some disruptions with a short warning time may be unavoidable. For these cases, a fast time response disruption mitigation method is essential. Experimental tests on a prototype system of a novel, rapid time-response disruption mitigation system being developed for tokamak-based reactors and as a backup option for ITER, referred to as the electromagnetic particle injector (EPI), have been able to verify the primary advantages of the concept. These are its ability to meet short warning time scales of <10 ms while attaining the projected high velocities for deep radiative payload penetration in reactor-scale plasmas. The EPI relies on an electromagnetic propulsion system. A metallic sabot is accelerated electromagnetically to the required velocities (>1 km s -1 ) within 2 ms, at which point it releases a radiative payload consisting of a shell pellet or well-defined microspheres. Initial experimental tests from the prototype system show attainment of over 600 m s -1 in about 1 ms. Finally, essential aspects of payload separation from the sabot and sabot capture have also been demonstrated at 200 m s -1 , and the method can be extended to over 2 km s -1 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Inception Based Deep Convolutional Neural Network for Remaining Useful Life Estimation of Turbofan Engines

Accurate estimation of the remaining useful life (RUL) is a key component of condition based maintenance (CBM) and prognosis and health management (PHM). Data-based models for the estimation of RUL are of particular interest because expert knowledge of systems is not always available and physical modeling is often not feasible. In this paper, a deep convolutional neural network (CNN) architecture is investigated for its ability to estimate the RUL of turbofan engines. The input to the model is a window of time series data collected from the engine under test. Inputting raw sensor data allows features to be learned instead of manually determined. To incorporate the ability to detect features of differing lengths, inception modules are used in the neural network architecture. The model is trained and tested using the new Commercial Modular Aero-Propulsion System Simulation (N-CMAPSS) data set and high prognosis accuracy was achieved. The developed model was used in the 2021 PHM Society Data Challenge and received second place, further validating its ability to accurately estimate RUL.

DeVol, Nathaniel↗

DOE OSTI2022

Evaluating Image Classification Deep Convolutional Neural Network Architectures for Remaining Useful Life Estimation of Turbofan Engines

Accurate estimation of the remaining useful life (RUL) is a key component of condition-based maintenance (CBM) and prognosis and health management (PHM). Data-based models for the estimation of RUL are of particular interest because expert knowledge of systems is not always available, and physical modeling is often not feasible. Additionally, using data-based models, which make decisions based on raw sensor data, allow features to be learned instead of manually determined. In this work, deep convolutional neural network (CNN) architectures are investigated for their ability to estimate the RUL of turbofan engines. To improve the accuracy of the models, CNN architectures, which have proven successful in image classification, are implemented and tested. Specifically, the blocks used in the Visual Geometry Group (VGG) architecture, inception modules used in the GoogLeNet architecture, and residual blocks used in the ResNet architecture are incorporated. To account for varying flight lengths, the input to the models is a window of time series data collected from the engine under test. Window locations at the climb, cruise, and descent stages are considered. To further improve the RUL estimations, multiple overlapping windows at each location are used. This increases the amount of training data available and is found to increase the accuracy of the resulting RUL estimations by averaging the estimates from all overlapping segments. The model is trained and tested using the new Commercial Modular Aero-Propulsion System Simulation (N-CMAPSS) data set, and high prognosis accuracy was achieved. Furthermore, this work expands on the model developed and used in the 2021 PHM Society Data Challenge, which received second place.

convolutional neural networks↗

DOE OSTI2026

Fleet-Level Fuel Impact of Hybrid-Electric Aircraft in United States

Here, this paper examines the impact of two potential solutions for increasing fuel efficiency and reducing emissions in commercial aviation: hybrid-electric propulsion and the use of drop-in synthetic aviation fuels (SAFs). The authors modeled three representative aircraft employed in the U.S. domestic market: a 70-seat regional turboprop, a 100-seat airliner, and a 180-seat airliner. These aircraft were retrofitted with hybrid-electric propulsion systems that integrate batteries and electric motors to provide additional torque to the propeller or fan. The authors explored various technological scenarios involving different battery specific energies, electric motor specific powers, and other relevant parameters. Flight performance models were used to analyze the range–payload capabilities of these new hybrid-electric aircraft and to compare them with their conventional counterparts. Subsequently, the authors virtually deployed the hybrid-electric aircraft on 2019 U.S. domestic commercial flights to assess the types and lengths of flights that could be serviced by this new fleet. We then compared the resulting fuel consumption, energy use, and emissions with those of a conventional fleet using a combination of jet fuel and SAF.

SAF↗

DOE OSTI2020

Fabrication of UN-Mo CERMET Nuclear Fuel Using Advanced Manufacturing Techniques

Ceramic-metallic nuclear fuels are a candidate fuel for nuclear thermal propulsion systems due to their high heat transport properties, which are necessary in very high-temperature environments. The conventional fabrication of uranium nitride–molybdenum fuel has been thoroughly studied in the past, but modern manufacturing techniques have presented a unique opportunity for further development within this field. This work demonstrates the use of advanced manufacturing techniques to produce nuclear fuel pellets composed of uranium nitride microspheres encased in a molybdenum matrix. Binder jetting is used to print molybdenum disks that are filled with uranium nitride microspheres and afterward sintered using spark plasma sintering. Two fuel pellets were fabricated to demonstrate the methodology and to provide a baseline analysis of the effects of temperature and pressure processing conditions. Characterization of the sintered fuel pellets includes detailed microstructural analysis and thermal conductivity measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Quantitative near-field water–air spray measurements at elevated pressures by neutron radiography imaging

Extensive experimental research on high-pressure spray has been conducted for decades to deepen our understanding and optimize its use in transportation, aviation, and propulsion applications; however, the near-field and in-nozzle flow characteristics are not fully understood. Dense near-field spray is among the most challenging diagnostic tasks since light is severely scattered and diffused by the liquid droplets and columns. In this work, the near-field spray and in-nozzle flow characteristics of an aeration nozzle at elevated pressures were characterized by neutron radiography imaging at the Oak Ridge National Laboratory High Flux Isotope Reactor. Neutron imaging benefits via strong penetration depths for some metals (i.e., aluminum, lead, and steel) and is sufficiently sensitive to detection of light elements, especially for hydrogen-based molecules, due to the large incoherent scattering cross section of neutrons. Both two-dimensional snapshots of the near-field spray and a three-dimensional tomographic scan of the nozzle geometry and in-nozzle water were obtained. This work provides new quantitative characterization of practical metal nozzle geometry for accurate boundary conditions, internal flow patterns inside the nozzle, and high-pressure spray flows. In conclusion, the findings may be used to improve performance and operating conditions of transportation vehicles and propulsion systems.

42 ENGINEERING↗

DOE OSTI2025

Hydrogen diffusion induced dislocation transformations in a nickel superalloy

The diffusion of hydrogen in metals and alloys induces embrittlement that can adversely affect the structural properties. We examine the adsorption and diffusion of hydrogen in Inconel-718 (IN-718), and scrutinize the ensuing effects on the dislocation behavior in the alloy to elucidate the fundamental mechanisms of hydrogen-microstructure interactions from classical molecular simulations. Hydrogen adsorption increases with time until the surface saturates, while hydrogen diffusion exhibits strong temperature dependence, with diffusion coefficients converging above 1300 K regardless of the initial hydrogen concentration in the alloy. The diffusion in IN-718 is significantly sluggish than in pure Ni, Fe, or Cr, and is strongly impacted by hydrogen concentrations, resulting in an order of magnitude higher diffusion coefficient for hydrogen (10-14 m2/s relative to 10-15 m2/s) at high concentrations, especially below 600 K. Hydrogen diffusion coefficient varies from 10-12 to 10-15 m2/s in IN-718 depending on temperature (500–1400 K). More critically, our results reveal that increasing hydrogen concentration induces microstructural changes in the alloy, transforming perfect dislocations into stair-rods and Shockley partials, with higher temperatures favoring the latter. The results are significant for hydrogen fuel applications to gain insights into the materials chemistry for designing safer and more efficient propulsion systems, particularly in high-performance environments related to controlled hydrogen combustion applications.

Banerjee, Tanumoy↗

DOE OSTI2024

CFD unified approach under Eulerian–Lagrangian framework for methanol and gasoline direct injection sprays in evaporative and flash boiling conditions

Innovative synthetic fuels for advanced propulsion systems, such as methanol and ammonia, and synthetic blended fuels (E00, E10, and E30), known for their high volatility, are often injected directly into combustion chambers. It follows that Eulerian–Lagrangian spray models need to accurately capture the spray collapse as a consequence of flash boiling onset and be capable of proficiently handling the preferential evaporation of multi-component fuels in evaporative scenarios. So, we performed the assessment of an Eulerian–Lagrangian CFD code for simulating methanol and E00 gasoline blend sprays in both early and late injection conditions involving flash boiling conditions and preferential evaporation. The adoption of an effervescent breakup model and of a non-equilibrium phase transition model for the discrete phase allows the adoption of a setup that is almost completely free from specific constant tuning, especially for what concerns the breakup model. We validated the simulations using experimental PLV maps of methanol and E00 sprays issued from the ECN Spray M injector. The results highlight a significantly different morphology of the methanol spray compared to the E00 one under late injection conditions. Under stratified combustion, low-volatile fuels are likely to be ignited first, and the flame propagates toward the high-volatile fuels. In conclusion, the spray collapse was also correctly reproduced, inducing the presence of a low-pressure zone and modifying the spray morphology.

E00↗

DOE OSTI2021

Measurements of the $^{5}D^{°}_{4}$–$^{5}P_{3}$ transition of singly ionized atomic iodine using intermodulated laser induced fluorescence

Iodine has been an element of recent interest for commercial use as fuel in electrostatic propulsion systems. A lingering problem when investigating ionized iodine using non-perturbative, laser-based techniques is determining the spectral width, i.e., the species temperature, of iodine. To this end, the hyperfine structure must be well understood to develop a spatially resolved diagnostic technique capable of ion flow and temperature measurements. Previous work investigated the lineshape of the transition between the $^{5}D^{°}_{4}$ and $^{5}P_{3}$ states of singly-ionized atomic iodine (I II) with laser induced fluorescence (LIF), but the hyperfine structure of the transition was unresolved in those measurements. In this work, an intermodulated LIF technique is used to measure an enhanced lineshape of the same I II transition. Here, a linear least squares fitting algorithm is used to fit the transition lineshape, where hyperfine transition locations and theorized relative amplitudes are constrained by theory. A lineshape model that incorporates hyperfine transition amplitude enhancement introduced from an intermodulated laser technique is implemented into the fitting function, as well as a nonlinear laser saturation effect. We report converged hyperfine coupling coefficients for these I II states.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗