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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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

A Lamination Model for Pressure-Assisted Sintering of Multilayered Porous Structures

This work describes a lamination model for pressure-assisted sintering of thin, multilayered, and porous structures based on the linear viscous constitutive theory of sintering and the classical laminated plate theory of continuum mechanics. A constant out-of-plane normal stress is assumed in the constitutive relation. The lamination relations between the force/moment resultants and the strain/curvature rates are presented. Numerical simulations were performed for a symmetric tri-layer laminate consisting of a 10% gadolinia doped ceria (Ce 0.9 Gd 0.1 O 1.95-δ ) composite structure, where porous layers were adhered to the top and bottom of a denser layer under uniaxially-applied pressures and the sinter forging conditions. The numerical results show that, compared with free sintering, the applied pressure can significantly reduce the sintering time required to achieve given layer thicknesses and porosities. Unlike free sintering, which results in a monotonic decrease of the laminate in-plane dimension, pressure-assisted sintering may produce an in-plane dimension increase or decrease, depending on the applied pressure and sintering time. Finally, the individual layers in the laminate exhibit different stress characteristics under pressure-assisted sintering.

42 ENGINEERING↗
DOE OSTI2018

Potential Experimental Topics for EGS Collab Experiment 3

To facilitate the success of FORGE, the DOE GTO has initiated a new research effort, the EGS Collab project, which will utilize readily accessible underground facilities that can refine our understanding of rock mass response to stimulation and provide a test bed at intermediate (~10 m) scale for the validation of thermal-hydrological-mechanical-chemical modeling approaches as well as novel monitoring tools. The first two EGS Experiments 1 and 2 are planned be performed under different stress/fracture conditions, and will evaluate different stimulation processes: Experiment 1 will focus on hydrofracturing of a competent rock mass, while Experiment 2 will concentrate on hydroshearing of a rock mass that contains natural fractures. Experiment 3 is scheduled to begin in 2019 will build off the lessons learned in Experiments 1 and 2 and will investigate alternate stimulation and operation methods to improve heat extraction in an EGS reservoir. This paper evaluates potential experiments that could potentially be conducted in Experiment 3. The two technical parameters defining energy extracted from EGS reservoirs with the highest economic uncertainty and risk are the production well flow rates and the reservoir thermal drawdown rate. A review of historical and currently on-going EGS studies has identified that over 1/2 of the projects have identified heat extraction challenges during their operation associated with these two parameters as well as some additional secondary issues. At present, no EGS reservoir has continuously produced flow rates on the order of 80 kg/s. Short circuiting (i.e. early thermal breakthrough) has been identified in numerous cases. In addition, working fluid loss (i.e. the difference between the injected fluid mass and the extracted fluid mass as compared to the injected mass) has been as high as 90%. Finally, the engineering aspects of operating a true EGS multi-fracture reservoir such as repairing/modifying fractures and controlling working fluid fluxes within multiple fractures for the effective EGS fracture management has not been sufficiently studied. To examine issues such as these, EGS Collab Experiment 3 may be conducted in the testbeds prepared for Experiments 1 and 2 by improving the previously performed stimulations, or conducted at a new site performing new stimulations with alternate method. Potential experiments may include using different stimulation and working fluids, evaluating different stimulation methods, using proppants to enhance permeability, and other high-risk high-reward methods that can be evaluated at the 10-m scale environment.

15 GEOTHERMAL ENERGY↗
DOE OSTI2018

An Overview of the EGS Collab Project: Field Validation of Coupled Process Modeling of Fracturing and Fluid Flow at the Sanford Underground Research Facility, Lead, SD

Enhanced Geothermal Systems (EGS) development will require an ability to accurately predict the flow rates and temperatures of the production wells. While simple in concept, complex heterogeneous fracture pathways can lead to channeling, short-circuiting, and premature thermal breakthrough complicating EGS. The EGS Collab project will establish a suite of intermediate-scale (~10-20 m) field test beds coupled with stimulation and interwell flow tests to provide a basis to better understand the fracture geometries and processes that control heat transfer between rock and stimulated fractures. These experiments will provide a means of testing tools, codes, and concepts that could later be employed under geothermal reservoir conditions at FORGE and in EGS. We will perform well-controlled, in situ experiments focused on rock fracture behavior and permeability enhancement. Pre- and post-test modeling of each test will allow for model prediction and validation. Comprehensive instrumentation will be used to collect high-quality, high-resolution geophysical and fracture characterization and fluid flow data. ,These data will be analyzed and compared with models and field observations to further elucidate the basic relationships between stress, induced seismicity, and permeability enhancement. To the maximum extent achievable, we will observe and quantify other key governing parameters that impact permeability, and attempt to understand how these parameters might change throughout the development and operation of an EGS project with the goal of enabling commercial viability of EGS. The Sanford Underground Research Facility (SURF) in South Dakota was selected as the EGS Collab project experimental site based on the evaluation of information from several sites. Our team has designed and constructed the first field experiment planned for this project, which is supported by the US Department of Energy’s Geothermal Technologies Office.

EGS, FORGE, field fracture stimulation and flow ex↗
DOE OSTI2020

The Data Foundry: Secure Collaboration for the Geothermal Industry: Preprint

The Data Foundry provides secure, cloud-based storage and universal access to digital information, enabling the greater geothermal industry to collaborate seamlessly with the Department of Energy (DOE), national labs, universities, and private organizations. Originally developed to support the EGS Collab project, the Data Foundry has been expanded to support FORGE, EDGE, and other DOE-funded projects, some collaborative, some private, by providing each project with a secure space and the ability to fine-tune individual access controls. In response to user feedback, it now also features improved integration with DOE’s Geothermal Data Repository (GDR), to provide a clear and convenient pathway from collaboration to publication, and to register collaborative data projects with well-known data registries like Data.gov and the National Geothermal Data System (NGDS). This paper will explore how recent concerns raised by data-centric, proprietary projects have informed development on the Data Foundry and highlight improvements designed to streamline workflows, improve access control, and promote the timely dissemination of information to the geothermal industry.

Data Foundry↗
DOE OSTI2013

International collaboration, the route to fuel cycle research and development

In hindsight, involvement with European Framework projects such as GoFastR (Gas-cooled Fast Reactors) and ACSEPT (Actinide Recycling by Separation and Transmutation) was a crucial and, at the time, an innovative step in maintaining the UK skills base during a period of major changes in the UK nuclear industry. It has undoubtedly delivered the objectives intended in terms of maintenance of the key skills, developing and training new staff, regenerating facilities and building strong links with the European nuclear research community. Over the last 2-3 years NNL's participation in European projects has moved forward such that NNL (National Nuclear Laboratory) is an integral partner of several major projects, fully engaged with delivering the core objectives of the projects and intent on forging deep collaborations with key organisations across Europe. With the renewed interest in nuclear energy and future fuel cycle options in the UK, NNL is now well positioned to contribute at an even deeper level in European level programmes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Neutron Irradiation of Nuclear Structural Materials Fabricated by Powder Metallurgy with Hot Isostatic Pressing

An irradiation campaign intended to produce data necessary to qualify various reactor structural materials fabricated by powder metallurgy with hot isostatic pressing (PM/HIP) is currently in progress. Manufacturing processes have considerable influence over the safety and integrity of nuclear reactor vessels and internal components. Established processes such as casting, plate rolling and welding, forging, drawing, and extrusion have been used to fabricate structural and pressure-retaining materials used in the nuclear power industry for the past 60 years. However, weldability and inspectability are ongoing issues in the manufacture of reactor vessels and internals. Furthermore, these components are subject to harsh service environments, which combine high radiation fluence, high temperature, and mechanical stress. These conditions can accelerate material degradation and failure, with the most extreme degradation often occurring at weldments and in poorly manufactured or inspected components. Advanced reactor designs and lifetime extensions to the existing fleet of light-water reactors (LWRs) will exacerbate materials degradation issues by increasing the duty on reactor internals. Thus, developing reliable manufacturing processes wherein high-quality weldments and inspections can be performed is of great importance to the continued safety and operation of nuclear power plants.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Structural Design Variations in Beetle Elytra

Abstract Beetles typically use their protective wing coverings or elytra to shield their membranous hindwings from the environment. Elytra in some terrestrial species have evolved a greater protective role capable of shielding the organism from powerful antagonistic predators. The structure–function relationships of these biological composites identify how architectural and chemical variations of the cuticle are tuned to create light‐weight, impact resistant composites. Specifically, the elytral structures of a tree dwelling beetle capable of flight, Trypoxylus dichotomus , and a terrestrial beetle incapable of flight, Phloeodes diabolicus , are compared to understand how their varied environmental needs forged the elytra to facilitate fight or resist fatal predator strikes. Mechanical and microstructural analysis reveals P . diabolicus has a harder, stiffer elytra that incorporate through‐thickness fibers to resist greater mechanical stresses imposed by bending and puncture. Conversely, the elytra of T . dichotomus have a compliant structure with large voids that facilitates localized deformation. Variations in flexural strength and puncture resistance remain attributed to P . diabolicus possessing a thicker cuticle with a greater degree of cross‐linking and an increased amount of endocuticular layers. These findings may provide useful insight into the design and manufacturing of composite materials for use in light‐weight or energy‐absorbing applications.

Rivera, Jesus↗
DOE OSTI2022

Case studies of robots and automation as health/safety interventions in small manufacturing enterprises

This article reviews the experiences of 63 case studies of small businesses (<250 employees) with manufacturing automation equipment acquired through a health/safety intervention grant program. The review scope included equipment technologies classified as industrial robots (n = 17), computer numerical control (CNC) machining (n = 29), or other programmable automation systems (n = 17). Descriptions of workers' compensation (WC) claim injuries and identified risk factors that motivated the acquisition of the equipment were extracted from grant applications. Other aspects of the employer experiences, including qualitative and quantitative assessment of effects on risk factors for musculoskeletal disorders (MSD), effects on productivity, and employee acceptance of the intervention were summarized from the case study reports. Case studies associated with a combination of large reduction in risk factors, lower cost per affected employee, and reported increases in productivity were CNC stone cutting system, CNC/vertical machining system, automated system for bottling, CNC/routing system for plastics products manufacturing, and a CNC/Cutting system for vinyl/carpet. Six case studies of industrial robots reported quantitative reductions in MSD risk factors in these diverse manufacturing industries: snack foods; photographic film, paper, plate, and chemical; machine shops; leather goods and allied products; plastic products; and iron and steel forging. Furthermore, this review of health/safety intervention case studies indicates that advanced (programmable) manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors, and improved process productivity in most cases.

42 ENGINEERING↗
DOE OSTI2018

SCC Initiation Behavior of Alloy 182 in PWR Primary Water

SCC initiation behavior of 15% cold forged specimens cut from four different alloy 182 weldments was investigated in 360°C simulated PWR primary water under constant load at the yield stress using direct current potential drop to perform in-situ monitoring of SCC initiation time. Within each weldment, one or more specimens underwent SCC initiation within 24 hours of reaching full load while some specimens had much longer initiation times, in a few cases exceeding 2500 hours. Detailed examinations were conducted on these specimens with a focus on different microstructural features such as preexisting defects, grain orientation and second phases, highlighting an important role of microstructure in crack initiation of alloy 182.

Alloy 182↗
DOE OSTI2022

Celestial amplitudes as AdS-Witten diagrams

Both celestial and momentum space amplitudes in four dimensions are beset by divergences resulting from spacetime translation and sometimes scale invariance. In this paper we consider a (linearized) marginal deformation of the celestial CFT for Yang-Mills theory which preserves 2D conformal invariance but breaks both spacetime translation and scale invariance and involves a chirally coupled massive scalar. The resulting MHV celestial amplitudes are completely finite (apart from the usual soft and collinear divergences and isolated poles in the sum of the weights) and take the canonical CFT form. Moreover, we show they can be simply rewritten in terms of AdS 3 -Witten contact diagrams which evaluate to the well-known D-functions, thereby forging a direct connection between flat and AdS holography.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

Microstructure and Strengthening Mechanisms in an Ultrafine Grained Al-Mg-Sc Alloy Produced by Powder Metallurgy

Additions of Sc to an Al-Mg matrix were investigated, paying particular attention to the influence of Al3Sc precipitates and other dispersoids, as well as grain size, on mechanical behavior. Prior studies have shown that Sc significantly increases the strength of coarse-grained Al-Mg alloys. Prompted by these findings, we hypothesized that it would be of fundamental and technological interest to study the behavior of Sc additions to an ultrafine-grained (UFG) microstructure (e.g., 100’s nm). Accordingly, we investigated the microstructural evolution and mechanical behavior of a cryomilled ultrafine grained Al-5Mg-0.4Sc (wt pct) and compared the results to those of an equivalent fine-grained material (FG) produced by powder metallurgy. Experimental materials were consolidated by hot isostatic pressing (HIP’ing) followed by extrusion or dual mode dynamic forging. Under identical processing conditions, UFG materials generate large Al3Sc precipitates with an average diameter of 154 nm and spaced approximately 1 to 3 µm apart, while precipitates in the FG materials have a diameter of 24 nm and are spaced 50 to 200 nm apart. The strengthening mechanisms are calculated for all materials and it is determined that the greatest strengthening contributions for the UFG and FG materials are Mg-O/N dispersion strengthening and precipitate strengthening, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Interrogating the Effects of Hydrogen on the Behavior of Planar Deformation Bands in Austenitic Stainless Steel

The effects of internal hydrogen on the deformation microstructures of 304L austenitic stainless steel have been characterized using electron backscattered diffraction (EBSD), transmission Kikuchi diffraction (TKD), high-resolution scanning transmission electron microscopy (HRSTEM), and nanoprobe diffraction. Samples, both thermally precharged with hydrogen and without thermal precharging, were subjected to tensile deformation of 5 and 20 pct true strain followed by multiple microscopic interrogations. Internal hydrogen produced widespread stacking faults within the as-forged initially unstrained material. While planar deformation bands developed with tensile strain in both the hydrogen-precharged and non-precharged material, the character of these bands changed with the presence of internal hydrogen. As shown by nanobeam diffraction and HRSTEM observations, in the absence of internal hydrogen, the bands were predominantly composed of twins, whereas for samples deformed in the presence of internal hydrogen, ε -martensite became more pronounced and the density of deformation bands increased. For the 20 pct strain condition, α '-martensite was observed at the intersection of ε -martensite bands in hydrogen-precharged samples, whereas in non-precharged samples α '-martensite was only observed along grain boundaries. We hypothesize that the increased prevalence of α '-martensite is a secondary effect of increased ε -martensite and deformation band density due to internal hydrogen and is not a signature of internal hydrogen itself.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Aluminothermic Reduction Process Under Nitrogen Gas Pressure for Preparing High Nitrogen Austenitic Steels

The aluminothermic reduction casting process under nitrogen gas pressure to make austenitic Cr-Mn-N (Ni-free) and Cr-N (Ni/Mn-free) high nitrogen stainless steels was investigated. Thermodynamic simulation of the redox reaction depending on process parameters was performed. As a result, the optimal ratio of aluminum to oxygen in the initial powder mixture to obtain the highest yield of metal product with minimal aluminum nitride contamination was predicted to be slightly greater than the stoichiometric ratio of 1.125. Microstructures of aluminothermic 26Cr1N and 23Cr9Mn1N steels, prepared taking into account the results of thermodynamic simulation, were investigated by X-ray diffraction, metallography, and transmission electron microscopy. The as-cast microstructure was a pseudo-pearlite (layered ferrite-nitride mixture) in 26Cr1N steel and a ferrite-austenite with signs of discontinuous austenite decomposition in 23Cr9Mn1N steel. After hot forging and subsequent water quenching from 1200 °C, the microstructure was fully austenitic in both steels. Tensile tests of quenched 23Cr9Mn1N steel showed a combination of high strength (ultimate strength of 1324 MPa) and ductility (elongation of 27 pct). The results illustrate that the aluminothermic casting process for producing high nitrogen steel is competitive with the commonly used methods, such as pressure electroslag remelting, both in terms of cost and mechanical properties of manufactured steel.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure and Mechanical Behavior of High-Entropy Alloys

High entropy alloys (HEA) have generated interest in recent years due to their unique positioning within the alloy world. By incorporating a number of elements in high proportion, usually of equal atomic percent, they have high configurational entropy, and thus, they hold the promise of interesting and useful properties such as enhanced strength and alloy stability. The present study investigates the mechanical behavior, fracture characteristics and microstructure of two singlephase FCC high-entropy alloys (HEA's) CoCrFeNi and CoCrFeNiMn with some detailed attention given to melting, homogenization and thermo-mechanical processing. Ingots approaching 8 kg in mass were made by vacuum induction melting (VIM) to avoid the extrinsic factors inherent to small scale laboratory button samples. A computationally based homogenization heat treatment was given to both alloys in order to eliminate any solidification segregation. The alloys were then fabricated in the usual way (forging, followed by hot rolling) with typical thermo-mechanical processing parameters employed. Transmission electron microscopy (TEM) was subsequently used to assess the single phase nature of the alloys prior to mechanical testing. Tensile specimens (ASTM E8) were prepared with tensile mechanical properties obtained from room temperature through 800°C. Material from the gage section of selected tensile specimens was extracted to document room and elevated temperature deformation within the HEA's. Fracture surfaces were also examined to note fracture failure modes. The tensile behavior and selected tensile properties were compared with results in the literature for similar alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of Normalizing Temperature on Fracture Characteristic of Tensile and Impact Tested Creep Strength-Enhanced Ferritic P92 Steel

The high-temperature Cr-Mo creep strength-enhanced ferritic (CSEF) steels are mainly used in nuclear and thermal power plants. In the present investigation, a systematic study on fracture surface morphologies of tensile and impact tested specimens and mechanical properties of cast and forged (C&F) P92 steel was performed for various heat treatment conditions. The heat treatment was carried out in normalizing temperature range of 950-1150 °C and then tempered to a fixed tempering temperature of 760 °C. The effect of varying normalizing temperatures before and after tempering on microstructure evolution, tensile properties, Vicker’s hardness and Charpy toughness was studied. The normalizing temperature before and after tempering was having a noticeable effect on mechanical properties of as-received P92 steel. The fracture surface of impact and tensile tested samples was also studied for various normalizing temperatures with or without tempering. Fracture surface morphology was affected by the presence of secondary phase carbide particles. The fraction area of cleavage facets on the tensile fracture surface was found to be increased with an increase in the normalizing temperature. The fractured tensile specimens were characterized by transgranular ductile dimples, tear ridges and transgranular cleavage facets for various heat treatments. The fracture mode of impact tested samples was more complex. It showed both quasi-cleavage facets and ductile dimple tearing for various normalizing temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructural Evolution and Mechanical Properties of Ti-22Al-25Nb (At.%) Orthorhombic Alloy with Three Typical Microstructures

Microstructural evolution, tensile and creep behavior of Ti-22Al-25Nb (at.%) orthorhombic alloy with three typical microstructures were investigated. The three typical microstructures were obtained by different solution and age treatment temperatures and analyzed by the BSE technique. The tensile strengths of the alloy at room temperature and 650 °C were investigated. The creep behaviors of the three typical microstructures were also studied at 650 °C/150 MPa for 100 h in air. The phase transformation mechanisms in creep deformation were also found. The experimental results showed that the formations of the three typical microstructures were decided by the isothermal forging and heat treatment. It was supposed that the high-temperature solution treatment might be dominant for the volume fraction and diameter of the equiaxed particles. While the double age treatment would lead to lamellar O phases. Due to grain refinement strengthening, the equiaxed microstructure presented the best tensile strength and ductility. The fully lamellar microstructure had the best creep resistance than that of other microstructures. In this paper, the phenomenon of creep-induced α{sub 2} phase decomposition was occurred during creep deformation of the equiaxed microstructure.

36 MATERIALS SCIENCE↗