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A comprehensive test program to evaluate nonmetallic materials use in the Hanford Tank Farms is described in detail. This test program determines the effects of simultaneous multiple stressors at reasonable conditions on in-service configuration components by engineering performance testing.
This report details the design, fabrication, and testing of surveillance test articles aimed at assessing material damage in reactor-relevant environments for effective degradation management. Two types of surveillance test articles with reduced sizes were developed based on design algorithms and finite element modeling: welded design and interlocking design. A furnace heating setup was adopted to apply multiple thermal cyclic loading profiles on the test articles with a temperature range of 500°C - 700°C, while the strain response was monitored using a digital image correlation technique. The testing results demonstrated the successful capturing of expected strain range for welded design while machining tolerance should be improved to engage strain coupling in the interlocking design. Mid-term (500 hours) and long-term (1500 hours) cyclic tests were conducted on welded test articles. A constant strain range of ~0.6% was observed at the specimen with testing under 500 hours, while a gradual decrease of strain at specimen was observed after 500 hours. Non-destructive evaluation through X-ray computed tomography confirmed the microcracks in the welds at specimen-driver joints after cyclic test that caused the strain change. Creep testing of the specimen after long-term cyclic test revealed a short creep life than expected. A multi-profile cyclic test was also conducted on a test article and demonstrated consistent strain response under different temperature ramp rates. The report also briefly discussed the challenges and future research efforts to advance test article development for material surveillance.
Faculty of Engineering at Shoubra has been funded to start a project for manufacturing railway sleepers from plastic wastes and iron slag to replace imported wooden sleepers. In this paper, performance of wooden sleepers in tracks of Egyptian Railways, including high cost and material defects as well as reasons to find out a new sleeper will be presented. Previous studies for using composite materials in manufacturing railway sleepers are illustrated. Mechanical testing has been carried out to determine the important properties of the new mixture; hence results are compared with the minimum requirements of the international railway standards. Linear analysis has been conducted using 3D-SAP2000 software to simulate the actual performance of the proposed sleeper. It is found that the testing results are larger than the required values. Thus; it is concluded that the tested material is effective and adequate to be used in manufacture of railway sleepers.
As ever increasing amounts of renewable electricity enter the energy supply mix on a regional, national and international basis, greater emphasis is being placed on energy conversion and storage technologies to deal with the oscillations, excess and lack of electricity. Hydrogen generation via proton exchange membrane water electrolysis (PEMWE) is one technology that offers a pathway to store large amounts of electricity in the form of hydrogen. The challenges to widespread adoption of PEMWE lie in their high capital and operating costs which both need to be reduced through R&D. An evaluation of reported performance data in literature for PEMWE reveals that there are excessive variations of in situ performance results that make it difficult to draw conclusions on the pathway forward to performance optimization and future R&D directions. In order to enable the meaningful comparison of in-situ performance evaluation across laboratories there is an obvious need for standardization of materials and testing protocols. Herein, we address this need by reporting the results of a round robin test effort conducted at the laboratories of five contributors to the IEA electrolysis annex 30. The effort utilized common sets of test articles, materials, test cells, and employed a set of shared test protocols. The maximum observed deviation between laboratories at 1 A cm-2 at cell temperatures of 60 and 80 degrees C, was 27 and 20 mV, respectively. The deviation of the results from laboratory to laboratory was a factor of 2-3 higher than the lowest deviation observed at one single lab and test station. However, the highest deviations observed were 1/10th of those extracted by a literature survey on similar material sets. The biggest takeaways are that cell temperature control appears to be the most significant source of deviation between results, while care must be taken with respect to break in conditions and cell electrical connections for meaningful performance data.
Purpose: To accurately model different breast geometries using a tissue equivalent phantom, and to classify these tissues in a coherent x-ray scatter imaging system. Methods: A breast phantom has been designed to assess the capability of coded aperture coherent x-ray scatter imaging system to classify different types of breast tissue (adipose, fibroglandular, tumor). The tissue-equivalent phantom was modeled as a hollow plastic cylinder containing multiple cylindrical and spherical inserts that can be positioned, rearranged, or removed to model different breast geometries. Each enclosure can be filled with a tissue-equivalent material and excised human tumors. In this study, beef and lard, placed inside 2-mm diameter plastic Nalgene containers, were used as surrogates for fibroglandular and adipose tissue, respectively. The phantom was imaged at 125 kVp, 40 mA for 10 seconds each with a 1-mm pencil beam. The raw data were reconstructed using a model-based reconstruction algorithm and yielded the location and form factor, or momentum transfer (q) spectrum of the materials that were imaged. The measured material form factors were then compared to the ground truth measurements acquired by x-ray diffraction (XRD) imaging. Results: The tissue equivalent phantom was found to accurately model different types of breast tissue by qualitatively comparing our measured form factors to those of adipose and fibroglandular tissue from literature. Our imaging system has been able to define the location and composition of the various materials in the phantom. Conclusion: This work introduces a new tissue equivalent phantom for testing and optimization of our coherent scatter imaging system for material classification. In future studies, the phantom will enable the use of a variety of materials including excised human tissue specimens in evaluating and optimizing our imaging system using pencil- and fan-beam geometries. United States Department of Homeland Security Duke University Medical Center - Department of Radiology Carl E Ravin Advanced Imaging Laboratories Duke University Medical Physics Graduate Program.
Thermocouples are generally used to provide real-time temperature indications in instrumented tests performed at material and test reactors. Passive temperature monitors, such as Silicon Carbide (SiC) and melt wires, may be included in such tests as an independent technique of detecting peak temperatures experienced during irradiation. In less expensive static (drop-in) capsule tests, which have no leads attached for real-time data transmission, melt wires, and SiC temperature monitors (TMs) are essentially the only possibility for peak temperature indication. A melt wire involves placing materials (wires) of a known composition and melting temperature in a test. An inventory is maintained at Material Science Laboratory (MSL) for melt wires ranging in temperatures from 30°C to 1500°C. Unfortunately, melt wires are limited in that it can only detect whether a single temperature is or is not exceeded (melt wire melted or not). SiC TMs, which can also be used to detect peak irradiation temperatures, are advantageous because a single monitor can allow to determine the peak temperature reached within a relatively broad range (100 – 1200°C) resulting in accuracies within ±20°C. Irradiation temperature is determined by measuring a property change after isochronal annealing or during a continuously monitored annealing process using specialized equipment at MSL. Recent research has produced a passive monitor known as sublime temperature monitor. This passive sensor has the capability of recording temperature gradients and pinpointing exactly where a temperature is located along that gradient. Long measurement lengths are achieved with very high accuracy in the location of desired temperature measurements (±2 mm over a 1 m span); however, this sensor has not been deployed in a nuclear reactor. This article will focus only on passive temperature sensors currently being researched and implemented under the Advanced Sensors and Instrumentation (ASI) program at Idaho National Laboratory (INL).
Savannah River National Laboratory performed hydrogen generation rate (HGR) testing using Tank 22 actual-waste sample material. The main objective of the testing was to determine the thermolysis HGR for Tank 22 material with and without added glycolate. An important use of the data from actual-waste sample testing is to validate equations for the Savannah River Site Concentration, Storage, and Transfer Facility (CSTF) HGR being developed through simulated-waste testing. Not exclusive to providing data for model validation, the desired outcome of this testing was to demonstrate a negligible thermolytic HGR in Tank 22 from the contribution of glycolate from the future Defense Waste Processing Facility (DWPF) Nitric-Glycolic Acid (NGA) flowsheet to Tank 22. Tank 22 is the pathway for glycolate in the DWPF recycle stream to enter the CSTF. Testing with added glycolate used the estimated future concentration of glycolate based on DWPF recycle with limited Sludge Receipt and Adjustment Tank and Slurry Mix Evaporator (SME) material carry-over but without glycolate mitigation in the Recycle Collection Tank. Minor objectives include the determination of the impact of the glycolate source used in testing and the inclusion of sludge solids in testing.
Ceramic materials are known for their high hardness and strength but are limited by low toughness and sudden failure. Inspired by the microstructure of dental enamel, which features undulating rods that promote crack deflection and energy absorption, architected specimens were designed and manufactured. A bespoke ball-on-ring (BoR) testing apparatus measured the static biaxial rupture strength of these bioinspired materials. Additionally, impact testing with spherical steel projectiles assessed their behavior under dynamic conditions. Monolithic alumina specimens were compared to architected alumina reinforced with yttria-stabilized zirconia (YSZ) rods produced via direct ink write 3D printing. BoR tests revealed that monolithic alumina had a Weibull modulus of 10.53 and a characteristic strength of 372.3 MPa, while the composite specimens showed a Weibull modulus of 5.46 and a characteristic strength of 213.3 MPa. Although the composite failed at lower stresses and projectile velocities, it exhibited notable crack deflection and fracture resistance, with cracks being effectively interrupted by the rod inclusions. The composite specimens also resulted in fewer and larger fragments upon impact. Finite element simulations confirmed the effectiveness of the rod structures in enhancing fracture resistance.
An experimental irradiation campaign to investigate radiolysis behavior of ASNF was conducted using in situ gas monitoring of small, sealed stainless-steel vessels (mini-canisters) containing aluminum samples with adherent (oxy)hydroxide films under helium backfill. The samples were irradiated with gamma radiation from a Co-60 irradiator. The samples tested included aluminum plate assemblies with lab-grown (oxy)hydroxides as surrogates for fuel as well as an end cropping from an actual ASNF assembly retrieved from long-term wet storage. These experiments enabled investigation of the impacts of various fuel drying approaches on the radiolytic generation rate and measurement of the H 2 yield associated with a reactor exposed sample with reactor-formed (oxy)hydroxide. The resulting data can be incorporated into model development for ASNF in dry storage. This report presents the cumulative results from four surrogate assemblies tested after application of different preparation (drying) conditions as well as the ASNF cropping; some post-irradiation testing was included. The mini-canister results are compared to data from related experimental campaigns that also tested the impact of drying conditions using samples irradiated in glass ampoules and discusses implications of the combined data
Air filters designed to contain plutonium particulates while allowing hydrogen gas to escape are used in a variety of low flow rate applications in the nuclear industry. Examples include nuclear material storage containers, glove box bag-out bags and waste drums. Filter efficiency testing is essential to ensure filter performance, and yet the low testing flow rates present some challenges because the testing flow rates can be 5 to 6 orders of magnitude lower than those used to test large HEP A filter systems used in facility ventilation systems. Statistical analysis of low flow filter efficiency test results on nuclear material storage container filters has proven to be essential to ensure that the testing processes, test equipment, and filters meet the design requirements. This poster will describe the testing apparatus used to test nuclear material storage container filters and the use of statistical methods to analyze low flow filter efficiency test results.
The feasibility and design of a novel pumped storage system in a wastewater treatment facility is investigated. Analysis covers the added benefit of aeration, costs, and specifications. For the given sub-megawatt system, off-the-shelf runner designs are not available. This research builds on an existing pump-turbine research and design through a combination of introducing aeration into the operating processes, analysis of large format metal additive manufacturing, and testing and validation of a hydrokinetic turbine runner that uses the same response surface optimization methodology as the discussed pump-turbine design. Two concepts are generated and proposed along with a baseline scenario. Two potential site locations are provided with relevant information The Stickney Wastewater Reclamation Plant and The Navy Wastewater Treatment Plant, Joint Base Pearl Harbor-Hickam, Oahu Hawaii. Results show that aeration is the primary benefit of such a system. The system is capable of meeting the required dissolved oxygen (DO) levels in wastewater treatment. The system produces volume averaged DO levels between 1.2 and 1.4 mg/l. The system is shown to be a scalable open-loop system that can be sized for application. Area requirements of the system are acceptable due to the use of a single pedestal elevated tank The implementation timeline and nuances of this system are largely unknown. In attempt to reduce costs, advanced manufacturing methods are investigated. Investigation into advanced methods showed that mechanical properties of additive manufactured metals using a GMAW system produce equal results to wrought materials and have the potential to produce custom wear properties.
Thermocouples are generally used to provide real-time temperature indications in instrumented tests performed at materials and test reactors. Melt wires or paint spots are often included in such tests as an independent technique of detecting peak temperatures incurred during irradiation. In addition, less expensive static capsule tests, which have no leads attached for real-time data transmission, often rely on melt wires and paint spots as a post-irradiation technique for peak temperature indication. Unfortunately, these techniques are limited in that they can only detect whether a single temperature is or is not exceeded. Silicon carbide (SiC) monitors are advantageous because a single monitor can be used to determine the peak temperature reached within a relatively broad range (200 – 800°C). Although the use of SiC monitors was proposed more than five decades ago, the ultimate performance limits of this technique are not fully understood. The Nuclear Science User Facilities (NSUF) is the United States Department of Energy Office of Nuclear Energy's only designated nuclear energy user facility. Its mission is to provide nuclear energy researchers access to world-class capabilities and to facilitate the advancement of nuclear science and technology. This mission is supported by providing access to state-of-the-art experimental irradiation testing, post irradiation examination facilities, and high performance computing capabilities as well as technical and scientific assistance for the design and execution of projects. As part of an NSUF project, low dose silicon carbide monitors were irradiated in the Belgian Reactor 2 and were then evaluated both at the SCK•CEN and at Idaho National Laboratory's High Temperature Test Laboratory to determine their peak temperature achieved during irradiation. The technical significance of this work was that the monitors were irradiated to a dose that was significantly less than recommended in published literature. This paper will discuss the evaluation process, the irradiation test, and the performance of the low dose silicon carbide temperature monitors.
The microstructural development of mortar bars with silica glass aggregate undergoing alkali-silica reaction (ASR) under the conditions of American Society for Testing and Materials (ASTM) Standard Test C1260 was analyzed using scanning electron microscopy and qualitative X-ray microanalysis. Cracking in the aggregate, the hydrated paste, and the paste-aggregate interface was important in the development of the microstructure. Cracks were characterized according to their location, their relationship to other cracks, and whether they are filled with ASR gel. Expansion of the bars was approximately 1% at 12 days and 2% at 53 days. They fell apart by 63 days. The bars contained two zones, an inner region that was undergoing ASR and an outer and much more highly damaged zone that extended further inward over time. Evidence of ASR was present even during the period when specimens were immersed in water, prior to immersion in NaOH solution.
Material degradation in Advance Test Reactors (ATR) is governed by irradiation, corrosion, elevated temperature exposure and cyclic mechanical creep-fatigue loads. This degradation information during reactor operation condition is limited. Hence, material damage monitoring is a key aspect of the design, analysis and licensing of ATR components. The idea is to monitor material component operation conditions of component by using a surveillance test article. This test article is fabricated with bi-metal configuration with two different thermal expansion coefficients, and design is motivated by Simplified Model Test (SMT) specimen which can capture structure-like mechanical response. Upon raising temperature of the bi-metal test article configuration, expansion mismatch results tensile load on specimen. Thus, temperature dependent passively actuated loading is achieved. The idea is to place this surveillance test article in reactor at location ‘x’ to surveil the mechanical response at critical location ‘y’. By calibrating the test article design, material degradation at critical location can be surveilled through assessing the degradation in surveillance test article. This study presents test article development with different material combinations and follow-up experimental testing work through passively loading test article with temperature history. The test article geometry and observed test results are presented in presentation slides.
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In this work we investigated an energy-efficient biotemplated route to synthesize nanostructured FePO4 for sodium-based batteries. Self-assembled M13 viruses and single wall carbon nanotubes (SWCNTs) have been used as a template to grow amorphous FePO4 nanoparticles at room temperature (the active composite is denoted as Bio-FePO4-CNT) to enhance the electronic conductivity of the active material. Preliminary tests demonstrate a discharge capacity as high as 166 mAh/g at C/10 rate, corresponding to composition Na0.9FePO4, which along with higher C-rate tests show this material to have the highest capacity and power performance reported for amorphous FePO4 electrodes to date.
Le Chatelier in 1887 and Powers in 1947 demonstrated that the volume of nanoscale C-S-H (calcium silicate hydrate) particles formed during hydration is smaller than the combined volume of the reactants—the anhydrous Portland cement and water. Hydration has thus been considered as contractive. An experiment shows that the opposite is true above the nanoscale. The porous skeleton of cement paste expands as the growing C-S-H particles push each other apart, similar to crystal growth pressure. This is significant for high-performance concretes (HPC) with low water-cement ratios (w/c ≤ 0.4), where chemical self-desiccation lowers pore relative humidity by 40%, compared to just 1% in traditional concretes (w/c ≈ 0.5). Standard American Society for Testing and Materials (ASTM) C1608 tests, using 10 mm thick water-immersed specimens, show large shrinkage because the half-time of water ingress is many decades, unable to offset shrinkage-causing self-desiccation. The present experiment, using a laser microscopy-topography technique, proves the opposite—expansion, evidenced by measuring the length changes of water-immersed HPC shards 0.5 mm thick in which the diffusion halftime, only about one hour, allows continuous resaturation of pores, canceling self-desiccation. The faster diffusion (halftime of one hour) enables continuous pore resaturation, preventing shrinkage. When sealed with paraffin oil, the shards self-desiccate and shrink. These findings align with studies since 2015, showing that models excluding hydration expansion cannot fit test data across various specimen sizes and sealing conditions. The results suggest that standardized ASTM tests for the so-called chemical shrinkage in modern concretes with very low water-cement ratios are misleading and need revision.