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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

The heat transfer coefficient associated with a moving packed bed of silica particles flowing through parallel plates

Concentrating Solar Power (CSP) with thermal energy storage has the potential to be a renewable energy technology with long duration, inexpensive energy storage. Higher temperature operation increases the conversion efficiency and reduces the cost of energy storage. Several emerging CSP designs utilize particles as the solar receiver due to their high temperature stability and low cost. In some designs, the particles are also used as the thermal energy storage (TES) media. In either configuration, an energy transfer is required between the hot particles and the working fluid in the power cycle in a Particle-to-Fluid Heat Exchanger (PtFHX). Understanding the heat transfer between a moving packed bed and a stationary surface is critical to the successful design of a PtFHX. In this paper, a test facility is described in which a moving packed bed of silica sand with particle size 100–600 μm is introduced into the channel formed by two parallel plates, one of which is heated. The effective static thermal conductivity of the particles used for the test are separately measured over the entire range of test temperatures. The inlet and outlet bulk temperatures of the particle flow are measured as are the surface temperatures at several axial locations along the centerline of the plate. The result is the measurement of heat transfer coefficient as a function of temperature for several velocities. The uncertainty of the measurements is presented and the results are compared to model results found in the literature.

14 SOLAR ENERGY↗
DOE OSTI2026

Covalent adaptable networks for electrolyte–binder integration in recyclable lithium metal batteries

Lithium-metal batteries (LMBs) are considered a promising next-generation energy storage technology due to their exceptionally high energy density. However, the development of solid polymer electrolytes and cathode binders for LMBs faces critical challenges, including interfacial instability, poor recyclability, and growing environmental concerns. In particular, current systems often rely on non-recyclable components featuring permanently crosslinked networks and polyfluoroalkyl substances (PFAS), such as poly(vinylidene fluoride) (PVDF), which cause battery waste and environmental harm. Herein, we introduce a multifunctional covalent adaptable network (CAN) platform based on thermally reversible Diels–Alder (DA) chemistry, designed for dual functionality as a CAN-based electrolyte (CAE) and a CAN-based cathode binder. The CAE achieves high ionic conductivity and strong storage modulus (1.4 mS cm −1 and ∼ 10 5 Pa at room temperature, respectively) and enables stable long-term cycling in symmetric Li||Li cells for over 2000 h with low overpotential. When it is applied as a cathode binder in LiFePO 4 (LFP) composite electrodes (C-LFP), the CAN matrix significantly reduces interfacial resistance and enhances discharge capacity compared to conventional PVDF-based systems. Thermal treatment induces self-healing at the cathode–electrolyte interface, further improving contact and yielding a discharge capacity of 150 mAh g −1 at 0.5 C. Moreover, the dynamic CAN architecture allows efficient recovery and reuse of lithium salts from spent electrolytes through retro-DA reactions under mild conditions (∼80 °C), establishing a low-energy, cost-effective recycling pathway. In conclusion, this work presents a scalable and sustainable strategy for high-performance LMBs by integrating recyclability, interfacial healing, and PFAS-free design, offering a holistic solution aligned with circular economy principles and next-generation battery demands.

Diels–Alder↗
DOE OSTI2025

Advanced Materials & Manufacturing Technology (AMMT): Process understanding for qualifying LPBF 316H SS

Investigations were conducted in fiscal years (FY) 2023 and 2024 to gather relevant data sets addressing challenges related to qualifying 316H stainless steel (SS) for use in future nuclear reactors. This work was a collaborative effort involving researchers from Idaho National Laboratory (INL), Argonne National Laboratory (ANL), and Oak Ridge National Laboratory (ORNL). Key outcomes included: • Development of process-structure-property data sets to better understand the relationships between manufacturing processes, material structure, and performance characteristics. • Establishment of an in-situ monitoring system to link these various data sets together. • Detailed characterization of the raw material feedstock to further strengthen the understanding of process-structure and process-property relationships. Building on this foundation, in FY25 there was interest in exploring the behavior of additively manufactured 316H SS under different test conditions to support the overall material qualification process. Los Alamos National Laboratory (LANL) was tasked with providing specimen samples to the collaborating labs, who then conducted a round-robin study examining factors like selective heat treatment, low-cycle fatigue (LCF), and tensile-creep (T-C) properties. Additionally, high-temperature differential scanning calorimetry (DSC) was performed by LANL to better understand how the material's thermal characteristics change as it is heated up to the melting point. This provided a more comprehensive understanding of the material's behavior. The combined results from these investigations could potentially be used to support the inclusion of 316H stainless steel in Section III, Division 5 of the relevant codes and standards, allowing its use in future nuclear reactor applications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Compact Counter Flow Fluidized Bed Heat Exchanger (Final Report)

Generation 3 concentrating solar power systems which utilize solid granular media as the heat transfer and storage media hold promise in reducing the levelized cost of electricity relative to generation 2 systems which utilize molten salt. The particles can be heated to temperatures exceeding 800 °C which enables the use of high efficiency supercritical CO 2 Brayton power cycles. A key challenge associate with the use of solid media is its low bulk thermal conductivity which limits the ability to transfer heat from the particles to a working fluid, such as supercritical CO 2 . Tradition shell and tube and shell and plate heat exchangers feature gravity driven particle flow which limits the maximum particle side heat transfer coefficient in these systems to approximately 400 W/m 2 K. A fluidized bed heat exchanger does not rely solely on gravity for particle flow. Instead, enhanced mixing and horizontal conveyance is achieved through fluidization induced through air injection at the bottom of a bed of particles. A tube bundle within the bed conveys the supercritical CO 2 which is heated via the turbulent particle motion at the tube wall.

14 SOLAR ENERGY↗
DOE OSTI2023

Heat transfer model for moving packed-bed particle-to-sCO 2 heat exchangers integrated with metal foams

Particle-to-supercritical carbon dioxide (sCO 2 ) heat exchangers (HXs) play a vital role in coupling heat transfer fluid (HTF) from high-temperature thermal receivers to power cycle working fluids (WF). Heat transfer enhancement is essential for adopting particle-based moving packed-bed heat exchangers (MPBHXs) in next-generation thermal energy storage (TES) systems, as MPBHXs usually exhibit low particle bed-to-wall heat transfer coefficients. High-porosity metal foams have shown their effectiveness in heat transfer enhancement. Here, this work presents a continuum heat transfer model to demonstrate the heat transfer enhancement in MPBHXs when the particle bed channel is filled with high porosity metal foams compared to open channel MPBHXs. The presence of metal foams increases the effective thermal conductivity in the particle channel and enhances the interstitial heat transfer coefficient between the moving particle bed and the stationary metal foams. The present model considers coupled two-dimensional (2D) heat transfer in the particle channel with metal foams and 1D heat transfer in the sCO 2 channel and the dividing wall. The temperature profiles for the particle bed, metal foam, dividing wall, and sCO 2 stream, as well as the local heat flux profiles between those, are studied in detail for various foam porosities, from which the particle bed-to-wall heat transfer coefficient, overall heat transfer coefficient, and total heat transfer rate for the MPBHX are determined. The effects of major MPBHX design and operating parameters on the particle bed-to-wall heat transfer coefficient and overall heat exchange capacity are thoroughly examined; thus, the MPBHX performance improvement with metal foams is quantified for each case. The present heat transfer model can provide valuable insights into the metal-foam MPBHX design and optimization, scale-up, and operating parameters selection.

42 ENGINEERING↗
DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to flexibly dispatch energy. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating solar thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also cascading lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and simulated using SimTech IPSEpro process modeling software. The design configuration depends on the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year; therefore, off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗
DOE OSTI2023

Design of a Geothermal Power Plant With Solar Thermal Topping Cycle: Preprint

Geothermal power plants are a reliable source of low-carbon power generation. However, modern electricity markets comprise relatively large proportions of variable renewable energy generation that may require power plants to dispatch energy flexibly. The power output, efficiency, and dispatch flexibility of a geothermal plant can be enhanced by integrating solar thermal energy into the system, as well as possibly compensating against ambient temperature variations. Concentrating Solar Thermal (CST) can generate temperatures much higher than conventional geothermal systems. Using a solar topping cycle is one way to efficiently convert high-temperature solar heat to electricity while also adding lower-temperature heat to the geothermal power cycle, thereby increasing its power output and possibly its efficiency. A hybrid power cycle design is proposed and is simulated using SimTech IPSEpro process modelling software. The design configuration depends upon the expected temperature of the geothermal resource and the quantity of solar heat added at the design point. These design considerations are described and expected performance is calculated. The solar heat addition varies throughout the day and year, therefore off-design models are necessary to assess the impact of solar availability (and ambient temperature) on the power plant performance. Off-design models are developed and combined with hourly weather data to facilitate an evaluation of annual system performance.

concentrating solar power↗
DOE OSTI2021

On-Sun Testing of a High-Temperature Solar Receiver's Flux Distribution

Concentrated solar power (CSP) is a promising technology in transitioning to renewable energy because of its abundance in nature and thermal energy storage (TES) capability. Among the four types of available CSP technology, including parabolic trough, linear Fresnel, power tower, and parabolic dishes, a power tower using a central receiver has more potential to generate high-temperature heat in a scale supporting power cycles efficiency and achieve low levelized cost of energy (LCOE). Other than the conventional type of receiver design, the high-absorptive receiver concept developed and presented in this paper is novel in its design approach. The novel receiver design originated from National Renewable Energy Laboratory (NREL) consists of an array of solar flux absorb tubes. The solar absorb tubes require uniform flux distribution and in-depth flux penetration through the three different reflective sections of tubes in a hexagonal shape. To evaluate this unique receiver design and thermal performance, the flux distribution, flux uniformity, and intensity were numerically simulated using ansys fluent and SolTrace modeling program. On-sun testing has been done at NREL high flux solar testing facility, based on the computational analysis.

clean energy↗
DOE OSTI2022

Extending the low-temperature operation of sodium metal batteries combining linear and cyclic ether-based electrolyte solutions

Nonaqueous sodium-based batteries are ideal candidates for the next generation of electrochemical energy storage devices. However, despite the promising performance at ambient temperature, their low-temperature (e.g., < 0 °C) operation is detrimentally affected by the increase in the electrolyte resistance and solid electrolyte interphase (SEI) instability. Here, to circumvent these issues, we propose specific electrolyte formulations comprising linear and cyclic ether-based solvents and sodium trifluoromethanesulfonate salt that are thermally stable down to –150 °C and enable the formation of a stable SEI at low temperatures. When tested in the Na||Na coin cell configuration, the low-temperature electrolytes enable long-term cycling down to –80 °C. Via ex situ physicochemical (e.g., X-ray photoelectron spectroscopy, cryogenic transmission electron microscopy and atomic force microscopy) electrode measurements and density functional theory calculations, we investigate the mechanisms responsible for efficient low-temperature electrochemical performance. We also report the assembly and testing between –20 °C and –60 °C of full Na||Na 3 V 2 (PO 4 ) 3 coin cells. The cell tested at –40 °C shows an initial discharge capacity of 68 mAh g –1 with a capacity retention of approximately 94% after 100 cycles at 22 mA g –1 .

25 ENERGY STORAGE↗
DOE OSTI2021

Operating Characteristics of Metal Hydride-Based Solar Energy Storage Systems

Thermochemical energy storage systems, based on a high-temperature metal hydride coupled with a low-temperature metal hydride, represent a valid option to store thermal energy for concentrating solar power plant applications. The operating characteristics are investigated for a tandem hydride bed energy storage system, using a transient lumped parameter model developed to identify the technical performance of the proposed system. The results show that, without operational control, the system undergoes a thermal ratcheting process, causing the metal hydride concentrations to accumulate hydrogen in the high-temperature bed over time, and deplete hydrogen in the low temperature. This unbalanced system is compared with a ’thermally balanced’ system, where the thermal ratcheting is mitigated by thermally balancing the overall system. The analysis indicates that thermally balanced systems stabilize after the first few cycles and remain so for long-term operation, demonstrating their potential for practical thermal energy storage system applications.

25 ENERGY STORAGE↗
DOE OSTI2025

Role of Polymer Architecture in CO 2 Capture from Air Using Supported Poly(alkylenimine)s: Linear vs Branched Polymers

Direct air capture (DAC) of CO 2 coupled with geologic storage is a promising climate change mitigation strategy, with some applications employing amines supported on porous solids as CO 2 sorbents. While branched poly(ethylenimine) (PEI) is the standard benchmark amine material, it suffers from limited oxidative stability. Poly(propylenimine) (PPI), as an alternative, has previously demonstrated improved resistance to degradation under harsh oxidative conditions. Linear and branched PEI are commercially available, though at different molecular weights, while PPI is not commercially available. For this reason, a comparative study of all four polymers (linear PEI, branched PEI, linear PPI, branched PPI) has not been reported for DAC. In this study, we synthesize and compare low-molecular-weight (∼800 g/mol) linear (L) and branched (B) PEI and PPI supported on a model support, SBA-15 silica. These materials are evaluated for CO 2 adsorption under dry, DAC-relevant conditions (400 ppm of CO 2 , 30 °C). LPPI exhibited the highest amine efficiency at all loadings, reaching a maximum of 0.14 mmol CO 2 /mmol N, outperforming BPEI, while LPEI consistently showed the lowest uptake capacity. Temperature-programmed desorption reveals that the structure of the amine polymer impacts the CO 2 binding strength, with branched polymers displaying higher desorption energies of 102−111 kJ/mol. In situ infrared spectroscopy experiments show that all sorbents preferentially capture CO 2 as ammonium carbamate. Isobaric CO 2 uptake studies further underscore the influence of polymer mobility and support pore crowding on performance, while demonstrating the sorbents’ performance at elevated temperatures and CO 2 concentrations. All materials demonstrated good stability over 25 adsorption−desorption cycles using thermal regeneration in an inert gas purge, with only BPPI displaying a 10−11% decrease in capacity/amine efficiency during cycling, possibly due to the loss of low molecular weight, oligomeric amines. This is the first side-by-side comparison of the CO 2 sorption properties of linear and branched PEI and PPI with similar molecular weights. These findings highlight the significant role of polymer architecture in CO 2 capture efficiency and inform future designs of durable, high-performance DAC sorbents.

adsorbents↗
DOE OSTI2021

Thermomechanical fatigue resistance of low temperature solder for multiwire interconnects in photovoltaic modules

Novel interconnect technologies leveraging low melting temperature solders, such as multiwire interconnects, are being deployed in photovoltaic (PV) modules for improved reliability through interconnect redundancy and lower thermal loads during interconnection and lamination. However, the equivalency of standardized accelerated testing to field conditions has not yet been established for these emerging technologies. In this study, the thermomechanical fatigue resistance of low temperature solder alloys is investigated and compared to that of conventional SnPb to assess the acceleration behavior of these alloys. While InSn is shown to have sufficient thermomechanical fatigue resistance on the order of that of SnPb, these results indicate Sn–Bi alloys may have poor thermomechanical fatigue resistance at field conditions. The results also show that Sn–Bi alloys have thermal cycling acceleration factors of less than one. This indicates that the standardized accelerated thermal cycling test, such as that in IEC 61215, will produce misleading results for Sn–Bi alloys and that unique testing is required for this PV module architecture. Though accelerated thermal cycling may be a meaningful qualification test for SnPb solder joints, these results suggest that mechanical loading may be a more appropriate test for Sn–Bi multiwire interconnects. This is due to the distinct processing and geometry of multiwire interconnects which may allow for mechanical, rather than strictly metallurgical interconnections.

14 SOLAR ENERGY↗
DOE OSTI2020

$\mathrm{UPDATED}$ $\mathrm{U3SI2}$ thermal creep model and sensitivity analysis of the $\mathrm{U3SI2-SIC}$ accident tolerant $\mathrm{FUEL}$

U 3 Si 2 is a candidate accident tolerant fuel (ATF) replacement for UO 2 . U 3 Si 2 ’s high uranium density and high thermal conductivity are favorable properties in steady-state and accident conditions. Low power performance of this U3Si2-SiC concept fuel is compared to that of UO 2 -Zr4 fuels by implementing models that describe the properties of U 3 Si 2 and SiC-SiC into Idaho National Laboratory's (INL) fuel performance code, BISON. Included in these material models is a thermal creep model for U 3 Si 2 based on compressive creep data. The simulated results are in keeping with community knowledge that the U 3 Si 2 -SiC concept fuel may serve as a replacement for UO 2 -Zr4 fuels during steady-state operation, provided the mSiC layer remains under compression. Through a moderate power history and three 24-month fuel cycles, the mSiC layer remains under compressive stress through a burnup of 80 MWd/kgU. During low power operation, failure of the mSiC layer generally occurs prior to significant thermal creep in U 3 Si 2 . Generally, U 3 Si 2 creep is temperature sensitive and of little importance at the temperatures and stresses simulated during steady operation and during fuel-to-cladding contact. A parameter variation study including 11,520 individual simulations with variations in nominal fuel thermal creep rate, cladding thermal conductivity, cladding irradiation creep and swelling, cladding gap size, and cladding thickness demonstrated that research priorities for this ATF should revolve around reducing cladding thickness as a means to minimize cladding failure. Generally, despite advances in SiC-SiC compliance, the brittle nature of mSiC excludes U 3 Si 2 -SiC for use where fuel cladding contact may occur.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Thermodynamic analysis of a two-stage binary-fluid ejector heat pump water heater

Ejector heat pump water heaters (EHPWHs) could significantly increase the thermal efficiency of domestic water heating and reduce greenhouse gas emissions. This study addresses two major technical barriers to using EHPWHs in domestic water heating—low heating cycle coefficient of performance (COP) and low condensation temperatures—using binary fluid pairs as a working fluid in a two-stage ejector system. A comprehensive, geometry-free model of binary-fluid ejectors was built and validated to predict the entrainment ratios of binary-fluid ejectors. A thermodynamic model of a two-stage binary-fluid ejector EHPWH was built to predict the heating cycle COP of EHPWHs. The performance of the EHPWH was theoretically evaluated using HFE7000 and Novec649 as primary fluids and R600 and R1234ze(Z) as secondary fluids. HFE7000/R600 gave the highest heating cycle COP (i.e., 1.356) in producing domestic hot water at 60.0 °C. An optimum evaporation temperature of the primary fluid was identified for the maximum effective entrainment ratio and effective pressure lift ratio of two-stage ejectors. Here, the effective entrainment ratio of the two-stage ejector dominated the heating cycle COP of the EHPWH. Primary fluids with lower latent heats of evaporation and/or secondary fluids with higher latent heats of evaporation yielded higher heating cycle COPs of EHPWHs.

42 ENGINEERING↗
DOE OSTI2022

Versatile Heat Transfer Module

Development of micro-reactors that can be easily transported to remote areas for civilian or military applications is an immediate focus of U.S. nuclear industry and therefore is being pursued by multiple reactor vendors (e.g. HolosGen LLC, Westinghouse, Ultra Safe Nuclear Corporation, URENCO, etc.) and actively supported by DOE-NE, DOE-ARPA-E and by the Department Of Defense (DoD). Very-high-temperature gas-cooled (VHTR) and heat pipe cooled reactor technologies are regarded as promising concepts for microreactors applications since they enable compact power conversion systems and display beneficial inherent safety features. Development of microreactors with enhanced performance must be supported by innovations in nuclear technologies. Several technologies being developed by the microreactor industry are being revisited with material technologies developed at the Argonne National Laboratory (ANL). Innovative high-temperature compatible solutions are developed to enable advanced thermal-spectrum microreactor designs featuring improved neutronics performance at high-temperature operating conditions to enable high thermal efficiency and economic competitiveness. This report focuses on the Versatile Heat Transfer Module (VHTM) technology that is developed at ANL for heat-transfer in thermal-spectrum microreactors. This technology is built on a liquid alkali metal heat pipe concept while leveraging advanced nuclear material technologies for high-temperature applications at reduced neutronic penalty with potential improvement in inherent safety behavior. The VHTM can be applied to design high-temperature thermal-spectrum microreactor systems with reduced size, weight, uranium enrichment, or increased lifetime. The INFINIT technology deriving from the VHTM enables design of a highly compact long-life microreactor concept for fission surface power (FSP). Demonstration of multiphysics modeling capability was also completed to showcase the added inherent safety benefits obtained with this concept. The VHTM technology remain at an early development stage with low Technology Readiness Level and Manufacturing Readiness Level. The current demonstration of these technologies has focused on manufacturing capability, on performance of the hydrogen diffusion barrier under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature VHTM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration. Such research is critical to pursue development of these technologies that have the clear potential to significantly improve the performance of currently investigated micro-reactors systems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

METHOD FOR EXPOSING IRRADIATED FUEL CLADDING TO RAPID THERMAL TRANSIENTS

Reactor core materials exposed to rapid thermal transients during accidents can experience significant changes in mechanical properties as irradiation hardness is recovered. Understanding material performance during transients using computer modeling requires accurate descriptions of mechanical property evolution with time and temperature. A simple experimental capability was developed to expose irradiated Zircaloy to a simulated thermal transient using immersion in molten tin (at 675°C) to rapidly heat and hold before rapidly cooling with a water quench. Multiple heating-cooling cycles using a nonirradiated tensile specimen showed simplicity and viability. Based on preliminary test results, a robust system was established for routine evaluation of simulated thermal accident scenarios in the Low Activation Materials Design and Analysis (LAMDA) laboratory at Oak Ridge National Laboratory (ORNL). This paper summarizes system development and nonirradiated Zircaloy commissioning test results. Future experiments will conduct tensile tests on irradiated Zircaloy after various rapid temperature profiles.

Byun, TS↗
DOE OSTI2025

Surviving nanoscale interfacial stability in extreme thermal expansion contrast Zn(CN) 2 -epoxy resin matrix composites

Here, we report the remarkable stability at the nanoscale matrix-filler interface in a series of overall low coefficient of thermal expansion (CTE) zinc cyanide (ZC)/epoxy resin composites. These interfaces demonstrate the stability of highly contrasting materials. These composites are designed to optimize the properties of both materials: epoxy resins are valued for their high strength, superb chemical resistance, low dielectric properties, and adhesive abilities. ZC, a model flexible framework, exhibits negative thermal expansion (NTE) behavior and compensates for the epoxy resin’s detrimentally large thermal expansion values. Filled resins minimize the native 65 ppm/°C CTE values to 19 ppm/° C over a wide temperature range while maintaining linearity, yielding composites compatible with typical metal and ceramic substrates’—commonly bonded to the resin— 0–20 ppm/° C CTE values. Additionally, with significant intrinsic differences in the materials, we use wide-angle X-ray diffraction and atomic force microscopy to elucidate thermal movement. The ZC/epoxy interface is surprisingly resilient over 1,000 cycles between -55° C and 75° C, extremes typical to aerospace applications. Further, we show that the resin viscosity remains less than 21 Pa*s at up to 30 vol% ZC, an important consideration for workability. We also discuss settling distribution, glass transition temperature, flexural strength, and longevity. All results point favorably towards practical implementation in low thermal expansion application needs: filling the gap in component design.

42 ENGINEERING↗