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

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

UNCERTAINTIES FOR IN-REACTOR TESTING OF TRITIUM LOADED GETTERS WITH TEMPERATURE CONTROL

The fourth experiment in TPBAR Materials Irradiation Separate-Effects Test (TMIST) series (TMIST-4) is planned to experimentally determine the effect of neutron irradiation on the equilibrium vapor pressure of tritium over a tritium loaded Nickel-Plated Zirconium (NPZ) getter in a simulated TPBAR service environment. This pressure will be used to estimate the tritium permeation rate. In the thermal design in the TMIST-4, two evaluations are required. 1) The cladding temperature is calculated to estimate the feasibility of detecting potential irradiation enhancement of the partial pressure for an NPZ getter. This work is required to obtain a precise cladding temperature for measurement of a low tritium partial pressure. This work has been completed and indicated that the required/target cladding temperatures based on the TMIST-4 test plan can be satisfied under the test condition range by modifying the capsule component shapes and inserting a thermally conductive metal sleeve. 2) The evaluation of uncertainties associated with the test design and operation is performed. This includes fabrication tolerances, and power and nuclear operating conditions. These factors will impact the component temperatures inside capsules and resulting the tritium partial pressure. The tritium permeation rate is a function of temperature and tritium partial pressure. The prediction of tritium permeation rates affects the feasibility of obtaining measurement resolutions required to reach reasonable conclusion for potential irradiation enhanced performance. This work will investigate the uncertainties.

TTP, TPBAR, TMIST-4, TPBAR Materials Irradiation S↗
DOE OSTI2020

Thermal Hydraulic Experimental Test Article (FY2020 Status Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed. Since the FY19 THETA status report, the THETA primary system components have been assembled and tested using de-ionized water. Some results of this testing at select Richardson and Reynolds numbers are included herein. The custom THETA sodium flowmeter (permanent magnet submersible sodium flowmeter) has been built and calibrated using sodium in an auxiliary facility against a NIST traceable vortex shedder type flowmeter. The permanent magnet flowmeter showed excellent performance, following the theoretical equation for measured voltage quite well, with an error < 3.5% at flow rates ranging from 3-24 GPM at temperatures up to 400 °C. The secondary sodium system for heat rejection from intermediate heat exchanger has been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger have been procured.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Design and out-of-pile testing of a novel irradiation experiment vehicle to support qualification of nuclear thermal propulsion components

Fission power systems have demonstrated higher thermal energy density per unit mass than chemical systems. High mass specific energy density offers advantages in space thermal propulsion applications. In the 1960s, nuclear thermal propulsion (NTP) development included the ROVER/NERVA program, in which full-scale prototype reactors were tested on the ground using hydrogen as the reactor coolant and propellant. NTP systems are being revisited, with expectations of improved performance resulting from improved fuel materials, allowing propellant temperatures near 2,800 K and over 20 thermal propulsion cycles. An apparatus has been developed to test NTP fuel materials in a research reactor at temperature and in a radiation environment typical of the NTP application. Here, this paper presents the design constraints, preliminary scoping thermal analysis, and basic thermal qualification testing for the out-of-pile experiment set apparatus, or OUTSET.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

Van de Graaff Irradiation of Materials

Through irradiations using our 3 MeV Van de Graaf accelerator, Argonne is testing the radiation stability of components of equipment that are being used to dispense molybdenum solutions for use as feeds to 99m Tc generators and in the 99m Tc generators themselves. Components have been irradiated by both a direct electron beam and photons generated from a tungsten convertor.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Status of the Top Plate and Anticryostat for High Field Cable Test Facility at Fermilab

Fermi National Accelerator Laboratory (Fermilab) is currently constructing a new High Field Vertical Magnet Test Facility (HFVMTF) designed for testing High Temperature Superconducting (HTS) cables under high magnetic fields. This facility is expected to offer capabilities similar to those of EDIPO at PSI and FRESCA2 at CERN. The background magnetic field of 15 T will be generated by a magnet supplied by Lawrence Berkeley National Laboratory. The primary function of HFVMTF will be to serve as a superconducting cable test facility, facilitating tests under high magnetic fields and a broad spectrum of cryogenic temperatures. Additionally, the facility will be utilized for testing high-field superconducting magnet models and demonstrators, including hybrid magnets, developed by the US Magnet Development Program (MDP). This paper provides a comprehensive description of the current status of two pivotal components of the facility: the Top/Lambda Plates Assembly and the Anticryostat for the Test Sample Holder. The latter will serve as a principal interface component connecting cable test samples with the facility's cryostat.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Initial results from the hotspot detection scheme for protection of plasma facing components in Wendelstein 7-X

One of the main aims of Wendelstein 7-X (W7-X), an advanced stellarator, is to investigate the quasi-steady state operation of magnetic confinement devices for nuclear fusion, for which power exhaust is an important issue. A dominant fraction of the energy leaving from the confined plasma region will be removed by 10 so-called island divertor units, which are designed to sustain a maximum heat flux of up to 10 MWm –2 . An essential prerequisite for the safe operation of a steady-state device is automatic detection of hot spots and other abnormal events. Simple temperature limits in infrared (IR) thermographic images will not be enough on their own, because of plasma-generated surface coatings and other effects summarized in the following. To protect divertor elements from overheating, and to monitor power deposition onto the divertor elements, near real-time hotspot detection algorithms for the analysis of carbon plasma facing components (PFCs) were implemented and tested in the GLADIS facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Thermal Hydraulic Experimental Test Article - Status Report FY20 Q2

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that will be used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility will simulate nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field will be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility is being designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary and secondary system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (like a redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. Figure 1 illustrates the main components of the primary system. THETA will be installed in the Mechanisms Engineering Test Loop (METL) with the primary system in the 28 inch Test Vessel #4, Figure 2. The design work for the facility has been completed, most primary component have been fabricated, primary components are being assembled in preparation for initial testing, and procurement is continuing with the secondary system components. Since the FY19 THETA status report, The THETA primary system components are at Argonne National Laboratory (ANL) and have been dry assembled. The secondary sodium system for heat rejection from intermediate heat exchanger has all been analyzed according to ASME code. All secondary side piping, fittings and a U-stamped air-to-sodium heat exchanger has been procured.

42 ENGINEERING↗
DOE OSTI2024

2023 Reftek Wrangler Digitizer Type Approval Evaluation

Sandia National Laboratories has tested and evaluated the Reftek Wrangler digitizer. The Wrangler digitizers are intended to record sensor output for seismic and infrasound monitoring applications. The purpose of this digitizer evaluation is to measure the performance characteristics in such areas as power consumption, input impedance, sensitivity, full scale, self-noise, dynamic range, system noise, response, passband, and timing. The Wrangler digitizers are being evaluated for potential use in the International Monitoring System (IMS) and On-site Inspection (OSI) components of Comprehensive Nuclear-Test-Ban Treaty (CTBT).

58 GEOSCIENCES↗
DOE OSTI2020

Vibrational processing of a dynamic structural flight system: A multichannel spectral estimation approach

Dynamic testing of large flight vehicles (rockets) is not only complex, but also can be very costly. These flights are infrequent and can lead to disastrous effects if something were to fail during the flight. The development of sensors coupled to internal components offers a great challenge in reducing their size, yet still maintaining their precision. Sounding rockets provide both a viable and convenient alternative to the more costly vehicular flights. Some of the major objectives are to test various types of sensors for monitoring components of high interest as well as investigating real-time processing techniques. Signal processing presents an extreme challenge in this noisy multichannel environment. The estimation and tracking of modal frequencies from vibrating structures is an important set of features that can provide information about the components under test; therefore, high resolution multichannel spectral processing is required. Finally, the application of both single channel and multichannel techniques capable of producing reliable modal frequency estimates of a vibrating structure from uncertain accelerometer measurements is discussed.

42 ENGINEERING↗
DOE OSTI2024

Elevated Temperature Graphite Mechanical Testing

High purity graphite will be used for core components within most High Temperature Reactor (HTR) designs. Several "high tech” industries currently utilize synthetic, high-purity, commercially available graphite components to fabricate photovoltaic cells, semi-conductors, optical fibers, and other high value electronic industry products. New advanced HTR designs are also interested in using these graphite grades for long-term, internal core component applications. Consequently, the US Department of Energy, Advanced Reactor Technologies (DOE-ART) program has spent several years testing different high purity graphite grades for potential use within these new nuclear reactor designs. A significant part of that effort has been in the development and improvement of American Society for Testing and Materials (ASTM) test standards specifically for nuclear graphite grades. Nearly all ASTM test standards have either been developed or improved by the DOE-ART program over the past 25 years. The ART program continues to assist in the development of new ASTM test standards in support of the future commercial HTR fleet currently being designed and built in the USA. The newest effort undertaken by ART is the development of high temperature mechanical testing practices that may be acceptable for a future ASTM test standard (or guide) for this critical material property measurement.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Lessons Learned about Liquid Metal Reactors from FFTF Experience

The Fast Flux Test Facility (FFTF) is the most recent liquid-metal reactor (LMR) to operate in the United States, from 1982 to 1992. FFTF is located on the DOE Hanford Site near Richland, Washington. The 400-MWt sodium-cooled, low-pressure, high-temperature, fast-neutron flux, nuclear fission test reactor was designed specifically to irradiate Liquid Metal Fast Breeder Reactor (LMFBR) fuel and components in prototypical temperature and flux conditions. FFTF played a key role in LMFBR development and testing activities. The reactor provided extensive capability for in-core irradiation testing, including eight core positions that could be used with independent instrumentation for the test specimens. In addition to irradiation testing capabilities, FFTF provided long-term testing and evaluation of plant components and systems for LMFBRs. The FFTF was highly successful and demonstrated outstanding performance during its nearly 10 years of operation. The technology employed in designing and constructing this reactor, as well as information obtained from tests conducted during its operation, can significantly influence the development of new advanced reactor designs in the areas of plant system and component design, component fabrication, fuel design and performance, prototype testing, site construction, and reactor operations. The FFTF complex included the reactor, as well as equipment and structures for heat removal, containment, core component handling and examination, instrumentation and control, and for supplying utilities and other essential services. The FFTF Plant was designed using a “system” concept. All drawings, specifications and other engineering documentation were organized by these systems. Efforts have been made to preserve important lessons learned during the nearly 10 years of reactor operation. A brief summary of Lessons Learned in the following areas will be discussed: Acceptance and Startup Testing of FFTF FFTF Cycle Reports

Wootan, David W.↗
DOE OSTI2016

High speed radiation tolerant data links

This project was slated to design and develop Rad-Hard IP components for 1Gb/s links and supporting hardware designs such as PLL, SER/DES, pad drivers and receivers and custom protocol hardware for the 1Gb/s channel. Also included in the proposal was a study of a hardened memory to be used as a packet buffer for channel and data concentrator components to meet the 1 Gb/s specification. Over the course of the proposal, technology change and innovation of hardware designs lead us away from the 1 Gb/s goal to contemplate much higher performance link IP which, we believed better met the goals of physics experiments. Note that CERN microelectronics had managed to create a 4.7 Gb/s link designed to drive optical fibers and containing infrastructure for connecting much lower bandwidth front-end devices. Our own work to that point had shown the possibility of constructing a link with much lower power, lower physical overhead but of equivalent performance that could be designed to integrate directly onto the front-end ASIC (ADC and data encoding) designs. Substantial overall power savings and experimental simplicity could be achieved by eliminating data transmission to data concentrators and data concentrators and related hardened buffering themselves, with conversion to optical media at a removed distance from the experiment core. We had already developed and tested Rad-Hard SER/DES components (1Gb in 130nm standard cells) and redundant Pad Drivers/Receivers (3+ Gb/s designed and measured performance), and had a viable 1Gb/s link design based on redundant a stuttered clock receiver and classical PLL, so the basic goals of the proposal had been achieved. Below, in chronological order, are the products and tools we constructed, as well as our tests and publications.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

A colorimetric method to measure in vitro nitrogenase functionality for engineering nitrogen fixation

Biological nitrogen fixation (BNF) is the reduction of N 2 into NH 3 in a group of prokaryotes by an extremely O 2 -sensitive protein complex called nitrogenase. Transfer of the BNF pathway directly into plants, rather than by association with microorganisms, could generate crops that are less dependent on synthetic nitrogen fertilizers and increase agricultural productivity and sustainability. In the laboratory, nitrogenase activity is commonly determined by measuring ethylene produced from the nitrogenase-dependent reduction of acetylene (ARA) using a gas chromatograph. The ARA is not well suited for analysis of large sample sets nor easily adapted to automated robotic determination of nitrogenase activities. Here, we show that a reduced sulfonated viologen derivative (S 2 V red ) assay can replace the ARA for simultaneous analysis of isolated nitrogenase proteins using a microplate reader. We used the S 2 V red to screen a library of NifH nitrogenase components targeted to mitochondria in yeast. Two NifH proteins presented properties of great interest for engineering of nitrogen fixation in plants, namely NifM independency, to reduce the number of genes to be transferred to the eukaryotic host; and O 2 resistance, to expand the half-life of NifH iron-sulfur cluster in a eukaryotic cell. This study established that NifH from Dehalococcoides ethenogenes did not require NifM for solubility, [Fe-S] cluster occupancy or functionality, and that NifH from Geobacter sulfurreducens was more resistant to O 2 exposure than the other NifH proteins tested. It demonstrates that nitrogenase components with specific biochemical properties such as a wider range of O 2 tolerance exist in Nature, and that their identification should be an area of focus for the engineering of nitrogen-fixing crops.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Process Control Plan to Monitor Acceptable Levels of Flux and other residues

IPC J-STD –001G, Amendment 1 requires that the assembler have a sampling plan to assure that the process remains in control once qualified and validated. It is well documented that electrochemical failures occur at component sites where flux residues are not fully activated. It is also well known that specific components have a higher risk of electrochemical failure. Selecting a control plan that monitors the process and its performance on challenging components provides assurance that the process maintains control once established during process qualification. The test board used to qualify the process establishes an upper and lower spec limit for each of the component types on the test board. Surface Insulation Resistance upper and lower control limits, using challenging components that are representative of production hardware, represent a golden process condition. The golden image is a measure of process deviations that represents the performance of a resistance curve within a specific period. The objective is to judge whether the process in or out of control.

42 ENGINEERING↗
DOE OSTI2022

Tailoring Corrosion Resistance of Additively Manufactured Metals with Atomic Layer Deposition

The goal of this work is to develop a scalable post-manufacturing capability at LANL that utilizes atomic layer deposition (ALD) for corrosion-resistant coatings onto additively manufactured (AM) metals. This will provide fundamentally new and essential capabilities towards the interchangeability of AM metals with traditionally wrought or machined material. This will be accomplished by (1) formulating novel ALD precursor doses and film thicknesses onto as-printed coupons of AM metals and (2) providing electrochemical characterization of corrosion susceptibility as a function of deposited film thickness. While ALD is well-established, the unique aspect (risk) of this work is application to rough AM surfaces. This risk is mitigated by repeating ALD deposition cycles, where thicker coatings laterally branch, resulting in a uniform coating. This risk will be assessed in the phase 1 feasibility study, wherein the application of ALD coatings to small AM coupon surfaces will be demonstrated using existing hardware and characterization tools at Sigma. This study alone will provide ground-breaking insight on the compatibility of ALD coating techniques with AM metals. Going beyond the phase 1 study, a standalone deposition chamber will be built, so full AM components can be coated and tested. While this MFR investment is focused on corrosion mitigation, it is critical to highlight external benefits of this technique outside the scope of this proposed study. ALD has extraordinary universality, whereby almost any material can be given almost any coating or graded density coating with atomic precision; and, the only limiting factors to scalability is the size of the dosing chamber. The self-limiting reactions intrinsic to ALD offers high conformity to part geometry and tolerance, even for internal surfaces where electroplating or conventional chemical vapor deposition falls short due to differential diffusion. This uniquely positions ALD at the forefront of post-manufacturing strategies for AM components, especially for those with complex geometry and internal surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Crashworthiness Models for Automotive Batteries

Safety is a key element of any device designed to store energy, particularly of electrochemical batteries, which convert energy of chemical reactions to electrical energy. Safety considerations are especially important when applied to large automotive batteries designed for propulsion of electric vehicles (EV). The high amount of energy stored in EV battery packs translates to higher probability of fire in case of severe deformation of battery compartment due to automotive crash or impact caused by road debris. While such demand for safety has resulted in heavier protection of battery enclosure, the mechanisms leading to internal short circuit due to deformation of the battery are not well understood even on the level of a single electrochemical cell. Moreover, not all internal shorts result in thermal runaway, and thus a criterion for catastrophic failure needs to be developed. This report summarizes the effort to pinpoint the critical deformation necessary to trigger a short via experimental study on large format automotive Li-ion cells subjected to large deformations as those occurring in deformation of battery module or pack. Mechanical properties of cell components were determined via experimental testing and served as input for constitutive models of Finite Element (FE) analysis. It has been rationalized that long-range stress fields occurring in spherical indentation of battery modules would trigger different deformation and failure scenarios compared to indentation of a single cell supported by a rigid flat surface. In order to investigate large deformations characteristic of battery module, a custom experimental set up has been built where the pouch cell was deformed against a compliant backing, which was represented by a ballistic clay. Experiments were also conducted on deformation of stacks of 10 pouch cells, - configuration representing half-module in Ford Focus EV battery pack without cooling plates and structural components. Comparison of the results shows promise for the compliant backing setup for safety evaluation of battery cells under more realistic conditions compared to indentation of single cell against undeformable backing where compression and electrode particle penetration through separator could be the major mechanism for short circuit.

25 ENERGY STORAGE↗
DOE OSTI2019

Testing thermal conductivity models with equilibrium molecular dynamics simulations of the one-component plasma

Equilibrium molecular dynamics simulations are used to calculate the thermal conductivity of the onecomponent plasma via the Green-Kubo formalism over a broad range of Coulomb coupling strength, 0.1 ≤ Γ ≤180. These simulations address previous discrepancies between computations using equilibrium versus nonequilibrium methods. Analysis of heat flux autocorrelation functions show that very long (6×10 5 $ω^{-1}_{p}$) time series are needed to reduce the noise level to allow ≲2% accuracy. The simulations provide accurate data for Γ ≲ 1. Furthermore, this enables a test of the traditional Landau-Spitzer theory, which is found to agree with the simulations for Γ ≲ 0.3. It also enables tests of theories to address moderate and strong Coulomb coupling. Two are found to provide accurate extensions to the moderate coupling regime of Γ ≲ 10, but none are accurate in the Γ ≳ 10 regime where potential energy transport and coupling between mass flow and stress dominate thermal conduction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2018

Guide to Nondestructive Evaluation Techniques

Nondestructive evaluation (NDE), alternately known as nondestructive examination (NDE), (commonly used within the nuclear industry), nondestructive testing (NDT) (commonly used in the aerospace and petrochemical industry), and nondestructive inspection (NDI) (commonly used within the military), are as the name implies test and assessment technologies designed to detect and characterize components without damaging or compromising the component’s ability to perform its design function. The most common application is detection of flaws caused either by manufacturing anomalies, service or environmental stresses, or natural material aging. More generally, applications may include estimation of mechanical and material properties, stress/strain, and dynamic response behavior. Post-manufacturing inspections frequently enjoy unfettered access to the component or part that may allow more thorough examinations, while in-service examinations after components have been in use may impose severe access limitations for in-situ testing. If flaws are detected, they must then be evaluated relative to their size, location, growth rate, growth mechanism, and likelihood that they are or will become a liability to the component’s function or performance. NDE is comprised of a large family of specific test disciplines including visual inspection, dimensional metrology, ultrasound, radiography, penetrant test, magnetic particle test, leak test, eddy current tests, potential drop tests, flash and vibro thermography, shearography, acoustic emissions, and many other methods. This section provides discussion on general NDE science and considerations for specific technique selection.

nondestructive, examination, inspection, NDE, NDT↗