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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Failure Analysis for Molten Salt Thermal Energy Storage Tanks for In-Service CSP Plants

Thermal Energy Storage (TES) is a fundamental component in concentrating solar power (CSP) plants to increase the plant's dispatchability, capacity factor, while reducing the levelized cost of electricity. In central receivers CSP plants, nitrate molten salts have been used for several years for operation temperatures of up to 565 degrees C. Despite many efforts to advance nitrate salt to higher operation temperatures (even considering a replacement with molten chloride salts) to achieve higher energy conversion efficiencies, the 565 degrees C temperature is currently considered the state-of-the art. Although molten salt tanks have been broadly deployed in commercial CSP plants worldwide, several failures have been reported in these tanks after a few months or years of operation, causing significant economic loss and mistrust in CSP technologies. Most of these failures are associated with the infancy of the technology and multiple issues related to tank design, fabrication, commissioning, and aggressive operation. A technical standard dedicated to the design and fabrication of molten nitrate TES tanks does not exist today. Current in-service molten salt tanks have been generally designed based on the American Petroleum Institute's (API) 650 and ASME Section II standards. The API 650 code provides guidelines for dimensions and fabrication for oil storage tanks up to 260 degrees C. The ASME standard provides allowable stress values for various materials at a range of temperatures and conditions. Both standards seem to be limited for molten salt TES tanks where high temperatures, thermal cycling, and transient conditions are expected. In 2020, NREL released the Concentrating Solar Power Best Practices Study (NREL/TP-5500-75763) that summarized multiple issues in CSP plants, along with potential alternatives and recommendations to address those issues based on information collected from participants representing about 80% of operating CSP plants in the world. One of the recommendations from this study was the development of accurate and validated models to evaluate the plant's transient operation, capable of capturing the effect of short-term clouds and operator response, while being flexible in being adapted to various spatial and temporal resource data. The "Failure Analysis for Molten Salt Thermal Energy Tanks for In-Service CSP Plants" project was inspired on this recommendation and was focused on (1) the development and validation of a physics-based model for a representative, commercial-scale molten salt tank, (2) performing simulations to evaluate the behavior of the tank as a function of typical plant operation conditions, (3) understanding tank failures mechanisms, (4) determining the residual stress and distortion in the tank floor after welding fabrication and evaluating their impact in the stresses developed in the tank during operation, (5) assessing the impact of key operation parameters on the temperature and stress distribution, (6) conduct a preliminary evaluation of design features to reduce stress and improve tank's reliability, and (7) estimate the tank's service life based on the stress developed under diverse operation scenarios. From the analysis conducted in the project and presented in this report, it was found that maximum stresses surpassing the yield strength point of the stainless steel (SS) 347H are developed on the tank floor near the perimeter. These large stresses are strongly influenced by the initial residual stresses and distortion of the tank floor after welding fabrication. During operation, large stresses are developed in the tank floor at high operation temperatures with large salt inventory levels during transient operation. High stresses are also related to elevated temperature gradients in the tank floor that could be attributed to insufficient mixing within the salt inflow and the salt inventory. Based on the analysis, creep is the predominant failure mechanism. However, the large stress levels could favor the plastic deformation into buckles, and crack formation due to stress relaxation cracking during cycle operation. A lifetime below 3 years was estimated for the typical plant operation conditions and a specific initial residual stress and deformation distribution of the tank floor. The estimated life agrees with the service time to failure reported in several commercial molten salt tanks. Desing and operation guidelines can be extracted from the analysis presented in this report, which could be adopted by tank manufacturers and CSP operators to advance toward an ultimate solution for tank failures by reducing residual and operational stresses to achieve a tank service life of more than 30 years. Addressing failures in molten salt TES tanks is fundamental for the CSP industry's survivability, but it is also important for other industrial and power generation applications using this technology, including nuclear and concentrating solar thermal.

14 SOLAR ENERGY↗
NASA NTRS1983

Mesospheric scatter and its microstructure

The difference in character between mesospheric returns from about 70 and about 80 km was noted. The 69-km echo is characterized by a single return with about .1 Hz width, while the 82.5 km return extends over more than 3 Hz bandwidth; this difference is also perceptible, but to a lesser degree, on the fading curves. The conclusion seems inescapable that internal random velocities of a few m/s are present within the scattering volume for the 82.5-km echo. The most likely source for these rather large velocities is convective instability arising from deformations of the temperature profile by breaking gravity waves. The distinction between the two types of scatter at these altitudes probably accounts for the behavior with frequency of the nightime fading period at low and very low frequencies. The fading period of D-region reflections at night was constant at about 7 min from 16 to 43 kHz, but that at frequencies of 70 kHz and above, the fading period decreased in such a way as to indicate the presence of irregularities smaller than about 1 km in size. This suggests that frequencies of 48 kHz and above, the fading period decreased in such a way as to indicate the presence of irregularities smaller than about 1 km in size. This suggests that frequencies of 48 kHz and below were reflected primarily from the region below 80 km where the narrow spectral irregularities dominate.

Bowhill, S. A.↗
NASA NTRS1991

Passive dynamic controllers for nonlinear mechanical systems

A methodology for model-independant controller design for controlling large angular motion of multi-body dynamic systems is outlined. The controlled system may consist of rigid and flexible components that undergo large rigid body motion and small elastic deformations. Control forces/torques are applied to drive the system and at the same time suppress the vibration due to flexibility of the components. The proposed controller consists of passive second-order systems which may be designed with little knowledge of the system parameter, even if the controlled system is nonlinear. Under rather general assumptions, the passive design assures that the closed loop system has guaranteed stability properties. Unlike positive real controller design, stabilization can be accomplished without direct velocity feedback. In addition, the second-order passive design allows dynamic feedback controllers with considerable freedom to tune for desired system response, and to avoid actuator saturation. After developing the basic mathematical formulation of the design methodology, simulation results are presented to illustrate the proposed approach to a flexible six-degree-of-freedom manipulator.

Juang, Jer-Nan↗
NASA NTRS1991

Passive dynamic controllers for non-linear mechanical systems

A methodology for model-independent controller design for controlling large angular motion of multi-body dynamic systems is outlined.The controlled system may consist of rigid and flexible components that undergo large rigid body motion and small elastic deformations. Control forces/torques are applied to drive the system, and at the same time suppress the vibrations due to flexibility of the components. The proposed controller consists of passive second-order systems which may be designed with little knowledge of the system parameters, even if the controlled system is non-linear. Under rather general assumptions, the passive design assures that the closed loop system has guaranteed stability properties. Unlike positive real controller design, stabilization can be accomplished without direct velocity feedback. In addition, the second-order passive design allows dynamic feedback controllers with considerable freedom to tune for desired system response, and to avoid actuator saturation. After developing the basic mathematical formulation of the design methodology, simulation results are presented to illustrate the proposed approach applied to a flexible six-degree-of-freedom manipulator.

Juang, Jer-Nan↗
NASA NTRS1993

Stress stiffening and approximate equations in flexible multibody dynamics

A useful model for open chains of flexible bodies undergoing large rigid body motions, but small elastic deformations, is one in which the equations of motion are linearized in the small elastic deformations and deformation rates. For slow rigid body motions, the correctly linearized, or consistent, set of equations can be compared to prematurely linearized, or inconsistent, equations and to 'oversimplified,' or ruthless, equations through the use of open loop dynamic simulations. It has been shown that the inconsistent model should never be used, while the ruthless model should be used whenever possible. The consistent and inconsistent models differ by stress stiffening terms. These are due to zeroth-order stresses effecting virtual work via nonlinear strain-displacement terms. In this paper we examine in detail the nature of these stress stiffening terms and conclude that they are significant only when the associated zeroth-order stresses approach 'buckling' stresses. Finally it is emphasized that when the stress stiffening terms are negligible the ruthlessly linearized equations should be used.

Padilla, Carlos E.↗
NASA NTRS1944

The Frictional Force with Respect to the Actual Contact Surface

Hardy's statement that the frictional force is largely adhesion, and to a lesser extent, deformation energy is proved by a simple experiment. The actual contact surface of sliding contacts and hence the friction per unit of contact surface was determined in several cases. It was found for contacts in normal atmosphere to be about one-third t-one-half as high as the macroscopic tearing strength of the softest contact link, while contacts annealed in vacuum and then tested, disclosed frictional forces which are greater than the macroscopic strength.

Holm, Ragnar↗
NASA NTRS2008

L-Band Transmit/Receive Module for Phase-Stable Array Antennas

Interferometric synthetic aperture radar (InSAR) has been shown to provide very sensitive measurements of surface deformation and displacement on the order of 1 cm. Future systematic measurements of surface deformation will require this capability over very large areas (300 km) from space. To achieve these required accuracies, these spaceborne sensors must exhibit low temporal decorrelation and be temporally stable systems. An L-band (24-cmwavelength) InSAR instrument using an electronically steerable radar antenna is suited to meet these needs. In order to achieve the 1-cm displacement accuracy, the phased array antenna requires phase-stable transmit/receive (T/R) modules. The T/R module operates at L-band (1.24 GHz) and has less than 1- deg absolute phase stability and less than 0.1-dB absolute amplitude stability over temperature. The T/R module is also high power (30 W) and power efficient (60-percent overall efficiency). The design is currently implemented using discrete components and surface mount technology. The basic T/R module architecture is augmented with a calibration loop to compensate for temperature variations, component variations, and path loss variations as a function of beam settings. The calibration circuit consists of an amplitude and phase detector, and other control circuitry, to compare the measured gain and phase to a reference signal and uses this signal to control a precision analog phase shifter and analog attenuator. An architecture was developed to allow for the module to be bidirectional, to operate in both transmit and receive mode. The architecture also includes a power detector used to maintain a transmitter power output constant within 0.1 dB. The use of a simple, stable, low-cost, and high-accuracy gain and phase detector made by Analog Devices (AD8302), combined with a very-high efficiency T/R module, is novel. While a self-calibrating T/R module capability has been sought for years, a practical and cost-effective solution has never been demonstrated. By adding the calibration loop to an existing high-efficiency T/R module, there is a demonstrated order-of-magnitude improvement in the amplitude and phase stability.

Andricos, Constantine↗
NASA NTRS2008

Engineering Models Ease and Speed Prototyping

NASA astronauts plan to return to the Moon as early as 2015 and establish a lunar base, from which 6-month flights to Mars would be launched by 2030. Essential to this plan is the Ares launch vehicle, NASA s next-generation spacecraft that will, in various iterations, be responsible for transporting all equipment and personnel to the Moon, Mars, and beyond for the foreseeable future. The Ares launch vehicle is powered by the J-2X propulsion system, with what will be the world s largest rocket nozzles. One of the conditions that engineers carefully consider in designing rocket nozzles particularly large ones is called separation phenomenon, which occurs when outside ambient air is sucked into the nozzle rim by the relatively low pressures of rapidly expanding exhaust gasses. This separation of exhaust gasses from the side-wall imparts large asymmetric transverse loads on the nozzle, deforming the shape and thus perturbing exhaust flow to cause even greater separation. The resulting interaction can potentially crack the nozzle or break actuator arms that control thrust direction. Side-wall loads are extremely difficult to measure directly, and, until now, techniques were not available for accurately predicting the magnitude and frequency of the loads. NASA researchers studied separation phenomenon in scale-model rocket nozzles, seeking to use measured vibration on these nozzle replicas to calculate the unknown force causing the vibrations. Key to this approach was the creation of a computer model accurately representing the nozzle as well as the test cell.

Source record↗
NASA NTRS2011

Forest Biomass Mapping From Lidar and Radar Synergies

The use of lidar and radar instruments to measure forest structure attributes such as height and biomass at global scales is being considered for a future Earth Observation satellite mission, DESDynI (Deformation, Ecosystem Structure, and Dynamics of Ice). Large footprint lidar makes a direct measurement of the heights of scatterers in the illuminated footprint and can yield accurate information about the vertical profile of the canopy within lidar footprint samples. Synthetic Aperture Radar (SAR) is known to sense the canopy volume, especially at longer wavelengths and provides image data. Methods for biomass mapping by a combination of lidar sampling and radar mapping need to be developed. In this study, several issues in this respect were investigated using aircraft borne lidar and SAR data in Howland, Maine, USA. The stepwise regression selected the height indices rh50 and rh75 of the Laser Vegetation Imaging Sensor (LVIS) data for predicting field measured biomass with a R(exp 2) of 0.71 and RMSE of 31.33 Mg/ha. The above-ground biomass map generated from this regression model was considered to represent the true biomass of the area and used as a reference map since no better biomass map exists for the area. Random samples were taken from the biomass map and the correlation between the sampled biomass and co-located SAR signature was studied. The best models were used to extend the biomass from lidar samples into all forested areas in the study area, which mimics a procedure that could be used for the future DESDYnI Mission. It was found that depending on the data types used (quad-pol or dual-pol) the SAR data can predict the lidar biomass samples with R2 of 0.63-0.71, RMSE of 32.0-28.2 Mg/ha up to biomass levels of 200-250 Mg/ha. The mean biomass of the study area calculated from the biomass maps generated by lidar- SAR synergy 63 was within 10% of the reference biomass map derived from LVIS data. The results from this study are preliminary, but do show the potential of the combined use of lidar samples and radar imagery for forest biomass mapping. Various issues regarding lidar/radar data synergies for biomass mapping are discussed in the paper.

Sun, Guoqing↗
NASA NTRS2013

Modelling of Equilibrium Between Mantle and Core: Refractory, Volatile, and Highly Siderophile Elements

Siderophile elements have been used to constrain conditions of core formation and differentiation for the Earth, Mars and other differentiated bodies [1]. Recent models for the Earth have concluded that the mantle and core did not fully equilibrate and the siderophile element contents of the mantle can only be explained under conditions where the oxygen fugacity changes from low to high during accretion and the mantle and core do not fully equilibrate [2,3]. However these conclusions go against several physical and chemical constraints. First, calculations suggest that even with the composition of accreting material changing from reduced to oxidized over time, the fO2 defined by metal-silicate equilibrium does not change substantially, only by approximately 1 logfO2 unit [4]. An increase of more than 2 logfO2 units in mantle oxidation are required in models of [2,3]. Secondly, calculations also show that metallic impacting material will become deformed and sheared during accretion to a large body, such that it becomes emulsified to a fine scale that allows equilibrium at nearly all conditions except for possibly the length scale for giant impacts [5] (contrary to conclusions of [6]). Using new data for D(Mo) metal/silicate at high pressures, together with updated partitioning expressions for many other elements, we will show that metal-silicate equilibrium across a long span of Earth s accretion history may explain the concentrations of many siderophile elements in Earth's mantle. The modeling includes refractory elements Ni, Co, Mo, and W, as well as highly siderophile elements Au, Pd and Pt, and volatile elements Cd, In, Bi, Sb, Ge and As.

Righter, K.↗
DOE OSTI2024

Designing Track for Electrospinning Unit and Cost-Effective Laser Scanning System

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
DOE OSTI2024

Designing a track for an electrospinning unit and cost-effective laser scanning system

Nanofibers are produced in the Targeted Systems Department (TSD) by applying a large voltage to the nanofiber fluid and the collection apparatus known as the electrospinner. The fiber is then shot out of nozzles and collected onto the electrospinner into a nanofiber mat. The problem is that since the nozzle heads are stationary, there is non-uniform deposition of nanofiber on the collection drum leading to variation in thickness of the produced nanofiber mat. To mitigate this issue, a reciprocating mechanism is designed to move the nozzle along the drum collector along with the ability to vary its stroke length. This design was realized using Siemens NX and several parts were printed using a 3D printer, but is, as of writing, untested. Second project involved providing an alternative method to scan a large sample that had undergone certain surface deformation by beam interaction and detect out of plane deformation such as micro-scale swelling and surface roughness. Systems to carry out this scanning already exist; however, they are expensive and produce many files that need to be stitched together and are cumbersome to deal with. The solution is to create a scanning system using an already purchased scanning laser and linear stage motor. The laser and stage motor were combined to produce length results that aligned with a digital microscope but differing height results.

Ruffolo, Leopoldo↗
NASA NTRS1994

Hotspot evolution and Venusian tectonic style

Because hotspots represent an important manifestation of heat loss on Venus, their geological evolution is of fundamental importance for any attempt to understand Venusian tectonics. Eistla Regio is an approximately 7500-km-long, moderately elevated region inferred to overlie one or more large mantle upwellings or hotspots. It also contains many shield volcanoes and coronae believed due to the rise of thermal plumes in the mantle. Central Eistla Regio includes two large volcanoes, Sappho and Anala, and several coronae in close proximity. Detailed mapping in this region results in two conclusions of tectonic significance: (1) Sappho and Anala occur near the intersection of two major extensional deformation zones, and (2) the coronae are older than the large volcanoes. Several of the coronae occur as a chain along Guor Linea, one of the major extensional deformation zones. Stratigraphic relationships indicate that the coronae began forming very soon after the emplacement of the widespread regional plains materials. Thus Central Eistla Regio was the site of a swarm of plumes that first formed coronae and then later formed shield volcanoes. The expected result of such a swarm would be thermal thinning of the elastic lithosphere with time. However, model results, geological observations, and gravity data suggest that the change from coronae to shield volcanoes was accompanied by a thickening of the lithosphere with time. This thickening is interpreted to be the result of global cooling of the lithosphere following the most recent episode of near-global resurfacing. The global cooling must have occurred faster than local heating of the lithosphere due to the impingement of thermal plumes.

Mcgill, George E.↗
NASA NTRS1996

Surface Deformation and Coherence Measurements of Kilauea Volcano, Hawaii, from SIR-C Radar Interferometry

The shuttle imaging radar C/X synthetic aperture radar (SIR-C/X-SAR) radar on board the space shuttle Endeavor imaged Kilauea Volcano, Hawaii, in April and October 1994 for the purpose of measuring active surface deformation by the methods of repeat-pass differential radar interferometry. Observations at 24 cm (L band) and 5.6 cm (C band) wavelengths were reduced to interferograms showing apparent surface deformation over the 6-month interval and over a succession of 1-day intervals in October. A statistically significant local phase signature in the 6-month interferogram is coincident with the Pu'u O'o lava vent. Interpreted as deformation, the signal implies centimeter-scale deflation in an area several kilometers wide surrounding the vent. Peak deflation is roughly 14 cm if the deformation is purely vertical, centered southward of the Pu'u O'o caldera. Delays in the radar signal phase induced by atmospheric refractivity anomalies introduce spurious apparent deformation signatures, at the level of 12 cm peak-to-peak in the radar line-of-sight direction. Though the phase observations are suggestive of the wide-area deformation measured by Global Positioning System (GPS) methods, the atmospheric effects are large enough to limit the interpretation of the result. It is difficult to characterize centimeter-scale deformations spatially distributed over tens of kilometers using differential interferometry without supporting simultaneous, spatially distributed measurements of reactivity along the radar line of sight. Studies of the interferometric correlation of images acquired at different times show that L band is far superior to C band in the vegetated areas, even when the observations are separated by only 1 day. These results imply longer wavelength instruments are more appropriate for studying surfaces by repeat-pass observations.

Rosen, P. A.↗
DOE OSTI2024

Probing nuclear structure at the Electron-Ion Collider and in ultra-peripheral nuclear collisions

Within the Color Glass Condensate framework, we demonstrate that exclusive vector meson production at high energy is sensitive to the geometric deformation of the target nucleus and subnucleon scale fluctuations. Deformation of the nucleus enhances the incoherent cross section in the small |t| region. Subnucleon scale fluctuations increase the incoherent cross section in the large |t| region. In ultra-peripheral collisions (UPCs), larger deformation leads to a wider distribution of the minimal impact parameter B min required to produce a UPC. This, together with larger incoherent cross sections for larger deformation, results in smaller extracted radii. Our results demonstrate great potential for future studies of nuclear structure in UPCs and electron-ion collisions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

In situ high-energy X-ray study of deformation mechanisms in additively manufactured 316L stainless steel

A key structural material planned to be used in the core of the Transformational Challenge Reactor is the additively manufactured 316L stainless steel (AM 316L SS). While the deformation of conventionally-manufactured 316 SS have been extensively studied, the deformation mechanism of AM 316L SS is less known. Here the room-temperature tensile behavior of AM 316L SS was studied in situ using high-energy X-ray diffraction and X-ray tomography. Diffraction yielded the lattice strains and the dislocation densi-ties of the AM 316L SS, which were compared to those of a conventionally processed 316H SS. It was found that while the conventional 316H SS had three distinct deformation stages, namely stage II ather-mal hardening, stage III dynamic recovery, and stage IV, the AM 316L experienced only the stages III and IV after an initial transitional period. The plastic instability stresses (PIS), i.e. the true ultimate tensile strength, were nearly the same in both materials. The AM 316L had very low dislocation barrier strength throughout the plastic deformation, which, in combination with the invariant PIS, explained its high dis-location storage capability and the attractive combination of strength and ductility. Tomography revealed morphological changes of the built-in pores in the AM 316L during deformation and fracture, and it was concluded that large pores close to the surface might have significant roles in the necking stage.

316 stainless steel↗
NASA NTRS2003

Elevated Temperature Creep Deformation in Solid Solution <001> NiAL-3.6Ti Single Crystals

The 1100 to 1500 K slow plastic strain rate compressive properties of <001> oriented NiAl-3.6Ti single crystals have been measured, and the results suggests that two deformation processes exist. While the intermediate temperature/faster strain rate mechanism is uncertain, plastic flow at elevated temperature/slower strain rates in NiAl-3.6Ti appears to be controlled by solute drag as described by the Cottrell-Jaswon solute drag model for gliding b = a(sub 0)<101> dislocations. While the calculated activation energy of deformation is much higher (approximately 480 kJ/mol) than the activation energy for diffusion (approximately 290 kJ/mol) used in the Cottrell-Jaswon creep model, a forced temperature compensated - power law fit using the activation energy for diffusion was able to adequately (greater than 90%) predict the observed creep properties. Thus we conclude that the rejection of a diffusion controlled mechanism can not be simply based on a large numerical difference between the activation energies for deformation and diffusion.

Whittenberger, J. Daniel↗
DOE OSTI2020

Exploiting ultra-large linear elasticity over a wide temperature range in nanocrystalline NiTi alloy

Many shape memory alloys can support large recoverable strains of a few percent by reversible stress-induced martensite transformation, yet they behave non-linear within a narrow operating temperature range. Developing the bulk metallic materials with ultra-large linear elasticity over a wide temperature range has proven to be difficult. In this work, a material design concept was proposed, that is true elastic deformation and reversible twinning-detwinning deformation run in parallel to overcome this challenge. By engineering the residual internal stress to realize the concurrency of true elastic deformation and twinning-detwinning deformation, a bulk nanocrystalline NiTi that possesses an ultra-large linear elastic strain up to 5.1 % and a high yield stress of 2.16 GPa over a wide temperature range of 270 °C was developed. This study offers a new avenue for developing the metallic materials with ultra-large linear elasticity over a wide temperature range of 270 °C (from 70 °C to -197 °C).

36 MATERIALS SCIENCE↗