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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 OSTI2024

IASCC of 304 SS in BWR environments: Effects of post-irradiation annealing and surface condition

To investigate the impact of low-temperature post-irradiation annealing (PIA) on the stress corrosion cracking of neutron-irradiated 304 stainless steel, constant extension rate tests were conducted in simulated boiling water reactor normal water chemistry (BWR-NWC) and hydrogenated water chemistry (HWC) environments. Ten tensile samples, comprising five as-irradiated and five PIA specimens, were prepared by electropolishing the gauge section of electric discharge machined (EDM) samples. Here, the annealing treatment reduced the yield strength from approximately 550 MPa to around 425 MPa and significantly restored the ductility and the strain hardening capability of the alloy. Consequently, the susceptibility of this material to irradiation-assisted stress corrosion cracking (IASCC) was effectively mitigated, which is more prominent in HWC, as evident from fractography, which indicated a decreased propensity for intergranular (IG) fracture. Furthermore, it was observed that the polished surface facilitated crack initiation more readily than the EDM surface, suggesting that the EDM process suppressed crack initiation to some extent.

Crack initiation↗
DOE OSTI2022

(Project 18-15531) Repair and Mitigation of Chloride-Induced Pitting and Chloride-Induced Stress Corrosion Cracking in Used Spent Nuclear Fuel Dry Cask Canister Materials (Final Technical Report)

Several experimental techniques were utilized to understand the corrosion and SCC performance of possible techniques for repairing cracks and pits in SS304 utilized for dry cask storage of spent nuclear fuel. The repairs examined included cold spray, FSW, soldering, and VFAW. The corrosion and SCC assessment techniques utilized for comparing repairs against the base material were 4-pt bending SCC testing in boiling MgCl 2 at stress levels between 0 MPa and 350 MPa, immersion testing in 40% RH brine solution meant to mimic a service-like environment, SSRT SCC testing in 40% RH brine solution. For FSW alone, scanning electrochemical cell microscopy and microelectrochemical syringe cell were utilized to understand the corrosion performance across the weld, in the retreating/advancing sides, and base material. Based on the results of this study, the FSW and cold spray repair techniques proved most viable for SCC repair in SS304 dry cask storage applications and continuing research is highly recommended to understand and quantify in further detail their SCC performance compared to unrepaired SS304. Additionally, solder and VFAW (patch or incline) would not be recommended based on the corrosion and SCC findings in this study.

42 ENGINEERING↗
DOE OSTI2022

Quarterly Management Document – FY22, 3rd Quarter, Multi-pass Hybrid Laser Arc Welding of Alloy 740H

During the 3rd quarter of FY22, progress was made on modeling and simulation of deep penetration laser welding of Alloy 740H. Advances in the modeling of residual stress development arising from the calculated temperature field of the solidifying weld pool were made to understand the development of solidification cracking. Additionally, preliminary modeling of the temperature field within the weld pool of a wobbling laser heat source was performed. The maximum temperature of the weld pool was found to vary with time. These result will allow modeling of deep penetration laser welding using a wobbling laser to mitigate weld defects and cracking. Also, additional characterization of hybrid laser arc welds indicated that these welds were not defect-free as originally thought and the current HLA welds would not be acceptable under criteria outlined in the ASME Boiler and Pressure Vessel Code, Section IX. Therefore, additional welding trails with variation of the welding parameters and HLA welding configurations are required to produce welds acceptable under the Section IX criteria. It was shown that considerable reduction of HLAW defects had been achieved with each successive welding campaign. Therefore additional variation of HLAW parameters may still yield the desired defect-free welds, however, options for alternate HLAW configurations as well as plate preheating are outlined as contingency plans to obtain suitable welds. These additional (unplanned) HLAW trial may prevent subsequent milestones from being achieved within the original budget.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Additive engineering for robust interphases to stabilize high-Ni layered structures at ultra-high voltage of 4.8 V

Nickel-rich layered cathode materials promise high energy density for next-generation batteries when coupled with lithium metal anodes. However, the practical capacities accessible are far less than the theoretical values due to their structural instability during cycling, especially when charged at high voltages. Here we demonstrate that stable cycling with an ultra-high cut-off voltage of 4.8 V can be realized by using an appropriate amount of lithium difluorophosphate in a common commercial electrolyte. The Li||LiNi 0.76 Mn 0.14 Co 0.10 O 2 cell retains 97% of the initial capacity (235 mAh g -1 ) after 200 cycles. The cycling stability is ascribed to the robust interphase on the cathode. It is formed by lithium difluorophosphate decomposition, which is facilitated by the catalytic effect of transition metals. The decomposition products (Li 3 PO 4 and LiF) form a protective interphase. This suppresses transition metal dissolution and cathode surface reconstruction. It also facilitates uniform Li distribution within the cathode, effectively mitigating the strain and crack formation.

25 ENERGY STORAGE↗
DOE OSTI2022

The Toughness of High-Strength Steel Weld Metals

Low-temperature phase transformation (LTPT) welding consumables are a new class of welding wires developed to mitigate hydrogen-induced cracking in the welding of high-strength steels without preheating or postweld heat treatment. LTPT weld metals have a high strength, but their toughness needs further investigation. LTPT weld metals predominately contain a martensite microstructure, which is necessary to achieve high strength; however, martensitic weld metals containing oxide inclusions have relatively poor toughness. For this study, three welding processes — gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), and hot wire GTAW — were investigated. Optical microscopy, scanning electron microscopes, and transmission electron microscopes were employed for characterization. The role of the shielding gas in the formation of oxide inclusions in LTPT weld metals was investigated. The formation of oxide inclusions in the weld metals was related to the CO 2 in the shielding gas. When 100% Ar or a pure inert shielding gas mixture was used for all three welding processes, oxide inclusions were greatly reduced, and the weld metal toughness improved considerably, matching the base metal toughness. The mechanism by which inclusions promote fracture propagation in the weld metal was proposed.

36 MATERIALS SCIENCE↗
NASA NTRS2020

NASA Engineering and Safety Center Technical Bulletin No. 20-07: Evaluating and Mitigating Liner Strain Spikes in COPV's

Unexpected cracking and leaking in bonded composite overwrapped pressure vessel (COPV) liners occurring in recent test programs have been attributed to liner strain spikes observed through measurement and predicted by analysis. Diminished load transfer between the liner and composite overwrap can lead to localized excessive liner yielding in the dome section. This diminished constraint can occur due to yielding of the adhesive or a manufacturing unbond defect. COPVs should be assessed for susceptibility to this new failure mode.

Evaluating↗
DOE OSTI2020

Multi-physics modeling of injected nanoparticles effect on remediation of CO 2 leakage through cracks

One potential risk in CO 2 sequestration is the leakage of carbon dioxide, which can result in contamination of underground water, creating potential threats to existing ecosystems. The common leakage pathway is through the pre-existing fractures or discontinuities within cement in the wellbore, incurred by the environmental conditions imposed on the cement. Injecting nanoparticles into pre-existing cracks is one of the most recently proposed ideas for mitigating fracture propagation in cement CO 2 sequestration. To demonstrate the feasibility of this new technology, a numerical approach was taken in this work, as it is challenging to investigate it in a laboratory setting. We proposed a coupled ALE (Arbitrary Lagrangian–Eulerian)–DEM (Discrete Element Method)–peridynamic modeling strategy within the LS-Dyna package to investigate the intertwined interaction among the CO 2 fluid flow, native fluid (e.g., brine), particle clusters, and cracks within the cement. The numerical results demonstrate that injected nanoparticles can effectively reduce the pressure exerted on the crack surface. Accordingly, the potential fracture propagation at the crack tip would be reduced compared to corresponding cases without nanoparticels as pressurized by fluid flow. This result verifies the effectiveness of proposed nanoparticle injection technology. Finally, using this established modeling strategy, the effect of filling particles on the fracture mitigation for different crack geometries (e.g. particle cluster patterns, aspect ratio of crack aperture and length) and CO 2 reservoir pressure are examined. The result shows that injected particles successfully reduce the fracture propagation in these scenarios.

42 ENGINEERING↗
DOE OSTI2023

Hermeticity of SiC/SiC composite and monolithic SiC tubes irradiated under radial high-heat flux

Demonstration of hermetic SiC fiber–reinforced SiC matrix composite cladding under normal operating environments has been identified as one of the most critical feasibility issues for accident-tolerant fuel cladding in light-water reactors. This study provides critical experimental data needed for understanding the effects of irradiation on hermeticity. SiC composite and monolithic tubes were neutron-irradiated to 2 displacements per atom with and without a nominal radial heat flux of 0.6 MW/m2 to produce a simulated in-pile stress state for the normal operation of a light-water reactor. The through-thickness temperature gradient under irradiation results in a gradient in swelling, which causes a significant stress buildup. Such irradiation-induced stress was modeled using a commercial finite element analysis code. The radial heat flux–irradiation synergism was experimentally investigated by constructing a special irradiation capsule and evaluating the helium hermeticity of the specimens. The simulated stress state exhibited a near equi-biaxial tensile axial and hoop stress of ~150 MPa at the inner surface of the SiC composite tube. This stress level is potentially beyond the matrix cracking stress. Degradation of hermeticity of the SiC composite tubes was observed after irradiation, indicating irradiation-induced cracking, whereas the irradiated monolithic SiC tubes remained hermetic. In conclusion, the results indicate that loss of hermeticity caused by radiation-induced microcracking is a potential issue for SiC composite cladding, depending on the magnitude of the temperature gradients. Coating the outer surface of the cladding was identified as a mitigation strategy that might overcome the cracking issue.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Cold Spray for Mitigation and Repair of Spent Nuclear Fuel Dry Storage Canisters

The purpose of this work is to investigate the use of cold spray for repair and mitigation of chloride-induced stress corrosion cracking (CISCC) in dry cask storage system (DCSS) canisters to ensure their integrity far beyond their original license period. This report provides a viability analysis of cold spray for repair and mitigation of CISCC in DCSS canisters to extend canister life.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Solidification behavior and cracking mechanisms of Ru-containing BCC-B2 superalloys

Many precipitation-strengthened alloys are highly susceptible to cracking during additive manufacturing (AM), which often requires compositional adjustments to mitigate. Recently, it has been demonstrated that refractory BCC alloys can be precipitation strengthened with ordered Ru-containing B2 precipitates to temperatures exceeding 1200 °C. This motivates a study of the potential fabricability of quaternary and quinary refractory BCC-B2 alloys by AM using single track laser experiments. Alloys with greater than 9 at.% Ru exhibit crack formation upon cooling. Solidification cracking was observed in all Zr-containing alloys, which can be mitigated by substituting Hf. Furthermore, this cracking is attributed to the strong partitioning of Zr during solidification, as revealed by characterization of alloy solidus, liquidus, and partition coefficients. Hf 5 Ru 4 -Nb 63 V 28 is identified as a promising BCC-B2 composition with a high B2 solvus (>1300 °C) and solidus (1695 °C) along with a high resistance to cracking.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ion Size Effects on the Thermodynamic, Kinetic, and Mechanical Properties during Ion Exchange in Solid-State Electrolytes

Ion exchange offers a pathway to impose residual compressive stresses to mitigate the electro-chemo-mechanical cracking of solid-state electrolytes such as lithium lanthanum zirconium oxide. This study uses a coupled multiscale framework (integrating density functional theory (DFT), molecular dynamics (MD), and continuum modeling) to examine how exchange ion size influences stress, diffusion, fracture toughness, and electronic properties. Larger isovalent ions (Na + , Ag + , K + ) were exchanged with Li + , with DFT confirming their preference for octahedral 96h sites and a linear relationship between ion size and chemical free expansion coefficient. MD simulations reveal stress and concentration effects on exchange ion diffusivity at elevated temperatures, with Na + and Ag + maintaining favorable mobility while K + showing concentration-dependent clustering. Continuum modeling predicts the range of fracture strength improvements and the required ion exchange concentration profile. It was shown that a 5% surface exchange concentration can induce ∼0.6 GPa of surface compressive stress using Na + and ∼1.0 GPa of surface compressive stress using Ag + . On the other hand, larger ion exchange species may penalize Li + diffusivity by increasing the activation volume and activation energy. Interestingly, Na + has a negligible penalty on Li-ion diffusivity. The room temperature Li + ion diffusivity is reduced by ∼40% with Ag + ion exchange. Electronic band structure analysis shows no size-dependent change in the bandgap, though Ag + introduces localized defect states near the valence band maximum. This study highlights ion size as a key factor in optimizing LLZO properties, offering a framework to improve the solid-state battery performance.

Jagad, Harsh D. [Brown Univ., Providence, RI (Unit↗
DOE OSTI2023

Morphodynamics of dendrite growth in alumina based all solid-state sodium metal batteries

All solid-state batteries (ASSBs) with ceramic electrolytes and alkali metal anodes are a potential future energy storage technology for vehicle electrification and smart grids. However, uncontrollable dendrite growth toward ultimate short circuiting in solid electrolytes (SEs) has become a serious concern in the design of long-cycle, safe ASSBs, and the underlying mechanism has remained unclear. Here through multiscale imaging and morphodynamic tracking we show that Na dendrites grow in β''-Al 2 O 3 SEs through an alternating sequence of Na deposition and crack propagation. Atomic-scale imaging evidenced that electrochemical cycling causes massive delamination cracking along the Na + conduction planes, accompanied by the closure of neighboring conduction channels. In situ SEM observations revealed a dynamic interplay between Na deposition and crack propagation: Na deposition accumulates mechanical stress that induces cracking; cracking releases the local stress, which promotes further Na deposition. Thus, Na deposition and cracking alternatingly proceed until short circuits take place. A multiscale phase-field model is developed to recapitulate the morphodynamics of Na dendrite growth, predicting the tree-like fractal morphology of the growing dendrites. Importantly, our findings suggest that decoupling between Na deposition and cracking represents an important route to mitigate uncontrollable dendrite growth in ASSBs.

25 ENERGY STORAGE↗
DOE OSTI2021

Electron Beam Powder Bed Fusion Additive Manufacturing of Refractory Metals

The processing of refractory metals via additive manufacturing (AM) presents an opportunity to fabricatecomponents not possible through traditional powder metallurgy techniques. However, processing via AM isextremely challenging and there exist a host of technological limitations still unaddressed. Molybdenumand tungsten are two materials of particular interest for nuclear energy generation applications. Themajority of existing work on the processing of these materials is focused on laser powder bed fusion whereasa smaller body of work exists for electron beam melting AM. In general, material with acceptable densitycan be obtained via both routes however cracking is much more difficult to mitigate against. Strongcrystallographic fiber textures have been observed across a range of refractory systems. In this work wepresent our recent findings on electron beam melting AM of pure tungsten and molybdenum. Wedemonstrate that defect-free material can be obtained in both systems with appropriate processing. Strongbuild direction crystallographic texture fibers are observed in both systems. In molybdenum the fibertexture has direct impact on the resulting tensile behavior. These results demonstrate that electron beamAM is a suitable technology for processing these difficult to fabricate materials.

Fernandez-Zelaia, Patxi↗
NASA NTRS2003

Propulsion Health Monitoring for Enhanced Safety

This report presents the results of the NASA contract Propulsion System Health Management for Enhanced Safety performed by General Electric Aircraft Engines (GE AE), General Electric Global Research (GE GR), and Pennsylvania State University Applied Research Laboratory (PSU ARL) under the NASA Aviation Safety Program. This activity supports the overall goal of enhanced civil aviation safety through a reduction in the occurrence of safety-significant propulsion system malfunctions. Specific objectives are to develop and demonstrate vibration diagnostics techniques for the on-line detection of turbine rotor disk cracks, and model-based fault tolerant control techniques for the prevention and mitigation of in-flight engine shutdown, surge/stall, and flameout events. The disk crack detection work was performed by GE GR which focused on a radial-mode vibration monitoring technique, and PSU ARL which focused on a torsional-mode vibration monitoring technique. GE AE performed the Model-Based Fault Tolerant Control work which focused on the development of analytical techniques for detecting, isolating, and accommodating gas-path faults.

Butz, Mark G.↗
DOE OSTI2025

Mapping of fracture and ionic conductivity changes in ion implanted solid electrolytes: Insights from molecular dynamics

Ion implantation emerges as a promising technique to address the persistent challenge of lithium (Li) filament growth in solid-state electrolytes as it can induce compressive stresses inhibiting crack growth and deflect dendrites, de facto mitigating early electrolyte failure. In this study, we examine the potential paradox of ion implantation: while aiming to enhance electrolyte performance, the radiation damage associated with implantation might inadvertently compromise both the ionic conductivity and the intrinsic fracture toughness of the material, rendering the material unsuitable for battery applications. Specifically, we employed molecular dynamics simulations to examine the scope of the downsides of ion implantation, specifically: (i) reduced ionic conductivity (due to radiation-induced amorphization) and (ii) mechanical stability (due to radiation-induced embrittlement) in ion-implanted Li 7 La 3 Zr 2 O 12 (LLZO) solid-state electrolytes. We explore how radiation damage impacts LLZO’s crystalline structure, Li-ion diffusion, and fracture properties at various temperatures and radiation damage levels. The study aims to provide insights into the competing effects of ion implantation and suggest potential engineering strategies for developing more robust solid-state electrolytes with improved conductivity and dendrite resistance.

Conductivity↗
DOE OSTI2021

Understanding Weld Formation and Microstructure Evolution in Laser Welded Stainless Steels and Ti-6Al-4V

High energy density welding processes are used for many industrial applications, such as aerospace and defense, and certain joint configurations and welding situations render post-weld inspection techniques difficult. Due to the inability to confirm penetration, there is a continual industrial need to improve prediction capabilities to aid in parameter selection. It is also necessary to understand the microstructural evolution to modify phase fractions and mitigate weldability related concerns such as solidification cracking or reduced corrosion performance.

42 ENGINEERING↗
DOE OSTI2022

Characterization of the Aerosol Source Term in Dry Storage Canisters

As long-term dry storage of used nuclear fuel at independent spent fuel storage installations (ISFSI) trends toward the de facto back end of the US fuel cycle, it becomes appropriate to investigate potential degradation and dispersion scenarios for suitable risk mitigation purposes. Pitting and subsequent stress corrosion cracking of the canister wall is currently viewed as a potential scenario leading to a through-wall pathway for contamination to be transferred from within the storage container to the surrounding environment. While stress corrosion cracking measurements are currently underway to further characterize this scenario, a parallel effort endeavors to perform a consequence analysis of conditions in which through wall cracks are indeed formed. This effort consists of engineering scale modeling using the GOTHIC and MELCOR software packages along with experimental depletion and penetration tests.

spent fuel storage, aerosol deposition, Stress Cor↗