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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 OSTI2018

Nuclear Power Plant Component Flooding Fragility Research

This report describes progress on Nuclear Power Plant component flooding fragility research conducted at the Component Flooding Evaluation Laboratory (CFEL). The progress includes additional steering committee membership and invitations, performance improvements to the Portal Evaluation Tank (PET), PET based experiments using industrial steel doors, pipe rupture spray pattern characterization, coupling the smoothed particle hydrodynamics (SPH) code Neutrino and the Idaho National Laboratory (INL) developed Risk Analysis Virtual Environment (RAVEN), continued development of component fragility mathematical models, and wave impact simulation device development, testing, and analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Updated Draft ASME Boiler and Pressure Vessel Code Case for Use of Alloy 617 for Construction of Nuclear Components for Section III Division 5

Early in the United States’ very high temperature reactor program, several candidate nickel alloys were considered for use in construction of the intermediate heat exchanger. Based primarily on technical maturity, a downselection was made to focus on Alloy 617. After this downselection, the primary goal of the research and development program was to develop sufficient information on the high temperature properties of the material to qualify it for construction of high temperature nuclear components in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (BPV) Code. Alloy 617 is a solid solution strengthened material with nominal Ni Cr Co Mo composition, originally developed for aerospace applications such as burner can liners for turbine engines by Huntington Alloys. (Huntington Alloys is now Special Metals Division of Precision Castparts, Inc.) The ASME BPV Code allows use of Alloy 617 for construction of non nuclear pressure vessels, and Alloy 617 is used in fossil fired power plants. Section III, Division 1, Subsection NB of the ASME BPV Code was developed for construction of nuclear components in light water reactors and allows use of ferritic materials up to 700°F and austenitic alloys up to 800°F. Subsection NH of Section III Division 1 was written to allow higher temperature construction with a primary focus on sodium cooled reactors. Recently, a new Division 5 of Section III was published specifically for high temperature reactors (regardless of the primary working fluid) and incorporates both Subsections NB and NH. There are only five alloys currently allowed for use in high temperature nuclear components: 2.25Cr 1 Mo and V modified 9Cr 1Mo steels, Types 304 and 316 stainless steels, and the high nickel austenitic Alloy 800H. This very sparse set of allowed materials is in contrast with the collection of more than 150 materials that are allowed for use in non nuclear pressure vessel construction. A draft Code Case to add Alloy 617 to the list of qualified alloys for use in high temperature nuclear design was submitted to ASME in the early 1990s, but it was withdrawn prior to formal Code action.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Process Development and Optimization of a Direct Cast U-6Nb 250 mm Hemispherical Component

Direct Casting is the process of casting a near-net shape part of U-6wt%Nb in a multi-zone VIM furnace for subsequent heat treatment and machining in to a final component. This report describes work to further develop a sound technical basis and best practices for mold design and process parameters for the Direct Casting of U-6Nb components with a hemispherical geometry. Specifically, process parameters and mold design are examined in detail for producing a 250 mm diameter hemisphere component. The goal is to efficiently produce a sound casting with a minimum of microporosity and uniform niobium composition. Prior work had tried unsuccessfully to cast this shape in a large single-coil vacuum induction melting (VIM) furnace. These castings had unacceptable levels microporosity and niobium segregation. In this work, this same part was cast in a multi-zone VIM and a sound casting was obtained. Beyond simply casting a sound part, this work aimed to optimize the hot-top design, metal pouring temperature, and mold pole temperature. Sound castings where produced using both a tapered and step hot-top designs. There were slightly lower porosity levels and about 5% better metal usage with the step hot-top so that design slightly better. With the current mold design, which uses a funnel and filter arrangement, there a large amount of superheat loss in the funnel/filter during mold filling. This temperature loss, and the apparent variability in the filling behavior, lead to casting defects in the pole region of several of the castings. The variability and defects were overcome by moving to a higher mold pole temperature (850°C) and a higher metal pour temperature (1500°C). For future work it is believed that a no-funnel design, with the filter integral to the crucible, will be a better and more robust strategy.

42 ENGINEERING↗
DOE OSTI2018

Additive Manufacturing of Sensors and Components for Non-Destructive Evaluation Applications

Additively manufactured machine components were designed for use in non-destructive evaluations. Additive manufacturing (3D printing) enables rapid production of simple or complex objects at a low cost for use in many fields of research and industry. 3D printed components were used to optimize an eddy current array probe to inspect various complex shaped objects, such as gears. Preliminary eddy current inspections were conducted to test the functionality and compatibility of the 3D printed components to the array probe and existing system. These were done by wrapping replica 3D printed gears with aluminum foil. The results were as expected, rough, uneven surface of the aluminum foil. Calibration scans were also executed to enable proper measurement of defect size in metal structures. For use in waveguide-based distributive sensing technologies, additively manufactured custom waveguides were designed for use in liquid environments to collect pressure and flow data. Waveguides were designed with membranes, thin sections of the walls, which would be pressed inward due to fluid pressure. Waveguide models continue to be developed and revised for most functional utility in liquid environments.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The NSLS-II Components Relative Alignment Deviation Estimate

The alignment of NSLS-II components will be conducted under the constraint of survey control network. The control network system is categorized as outside, primary and secondary control networks, and all of them have random errors due to measurement random errors. In the error propagation point of view, they all will contribute to the final positioning accuracy of each component in global sense. However, as the global positioning requirement is relative loose (i.e. ± 3mm for storage ring), relative positioning accuracy is what we really concern. In this situation, only secondary control network will contribute as only secondary monuments will be employed to direct the adjustment of components. Other error sources include instrument setup error, adjustment residuals and slab movement etc. This article will analyze the maximum relative deviation of 3 positions in one cell’s region, which is a simulation of 1 ID and 2 Vacuum chamber positions.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Survey on cladded component design procedures for nuclear and non-nuclear applications

Corrosion resistant weld overlay and integral claddings are used to provide corrosion resistance to components made of structural materials that are susceptible to corrosion. Generally, cladding is used in industry to offset the cost of expensive corrosion resistance alloys. In the application to nuclear, cladding provides a mechanism to allow use of limited code approved base materials in corrosive environments. Applicable design rules will need to be developed to support the design and construction of these cladded components for MSR applications. This document provides a survey of the state-of-the-art in design practice of cladded components for both the nuclear and non-nuclear industry. Design practice and service experience in the nuclear and non-nuclear is investigated. A gap analysis on applying these design practice to nuclear applications is included.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

ASC ATDM Level 2 Milestone #6358: Assess Status of Next Generation Components and Physics Models in EMPIRE

This report documents the outcome from the ASC ATDM Level 2 Milestone 6358: Assess Status of Next Generation Components and Physics Models in EMPIRE. This Milestone is an assessment of the EMPIRE (ElectroMagnetic Plasma In Realistic Environments) application and three software components. The assessment focuses on the electromagnetic and electrostatic particle-in-cell solutions for EMPIRE and its associated solver, time integration, and checkpoint-restart components. This information provides a clear understanding of the current status of the EMPIRE application and will help to guide future work in FY19 in order to ready the application for the ASC ATDM L1 Milestone in FY20. It is clear from this assessment that performance of the linear solver will have to be a focus in FY19.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Manufacturing of low-background copper electrical components for rare-event detection. Final report

This SBIR Phase I project developed the manufacturing capability for the production of ultra-low-background copper and lead for use in electronic interconnects and support architecture. Copper is an attractive electronic and support material because of its favorable conductivity and mechanical properties. Fortuitously, the material can also be electroplated with high radiopurity, particularly if the electroforming is performed in shielded, buried facilities within which the cosmogenic background is minimized. The machining of the electroformed copper into wires, feedthroughs, and support hardware can potentially introduce impurities through the shop environment or through the dies used in wire-drawing and part formation. During Phase I, we demonstrated an alternative low-cost solution-based approach in which copper nanoparticles are colloidally-grown and self-assembled into solids that can serve as thermal structures- such as cold-fingers, mechanical structures- such as the inner shielding lining, and electronic devices. We demonstrated ultrastrong, high-conductivity free-standing copper conductors during Phase I suitable for battery electrodes, interconnects, and cabling, all components that enable next-generation flexible electronics. In nanoparticle form, copper forms in a crystalline lattice with very low impurity content, but its self-assembly is facilitated by organic capping ligands that can serve as impurity sources. Upon the formation of a colloidal solid, the copper particles can be fused and the organic components evaporated through vacuum annealing. The study of ultra-pure copper was expanded during Phase I to include nanostructured lead, which is an important radiation-shielding material. By growing lead particles in a water-based solution the resulting solution can be poured into the desired form-factor mold, within which it will self-assemble and harden upon evaporation of the water and any organics. The effort during Phase II is designed to complete the development of the manufacturing process and to use that process to deliver high radio-purity copper and lead components to the rare-event detection community so that the noise-floor contribution from the surrounding materials is substantially eliminated.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Graph Theory and IC Component Design Analysis

Graph analysis in large integrated circuit (IC) designs is an essential tool for verifying design logic and timing via dynamic timing analysis (DTA). IC designs resemble graphs with each logic gate as a vertex and the conductive connections between gates as edges. Using DTA digital statistical correlations, graph condensation, and graph partitioning, it is possible to identify high-entropy component centers and paths within an IC design. Identification of high-entropy component centers (HECC) enables focused DTA, effectively lowering the computational complexity of DTA on large integrated circuit graphs. In this paper, a devised methodology termed IC layout subgraph component center identification (CCI) is used to identify described. CCI lowers DTA computationally complexity by condensing IC graphs into reduced subgraphs in which dominant logic functions are verified.

42 ENGINEERING↗
DOE OSTI2020

Imaging of Calibrated Defects in Additively Manufactured Materials: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. Currently, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. As a solution to NDE of AM, we are developing pulsed thermal imaging which is non-contact, one-sided, and scalable to arbitrary size and shape of the AM parts. Pulsed thermography (PT) system utilizes a high intensity flash lamp to rapidly heat surface of sample, and a high sensitivity fast-frame megapixel infrared (IR) camera to capture data of surface temperature variations. The acquired data cube consists of a stack of surface temperature images taken at different times. Information about material internal defects is extracted by analyzing the data cube. This report provides results of preliminary performance evaluation of pulsed thermal imaging capability in detection of imprinted flaws in AM metallic structures. The flaws were introduced into AM parts as imprinted hemispherical low density regions, consisting of trapped un-sintered metallic powder. Specimens for developed for this study consisted of AM stainless steel 316 and Inconel 718 plates. The diameters of imprinted defects varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. Pulsed thermal tomography (PTT) processes the measured data cube to obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. PTT has been previously used in imaging of similar size flat bottom hole (FBH) simulated defects in stainless steel 316 and Inconel 718 specimens. In the study involving AM specimens, PTT imaging results have shown that 1mm-diameter defects located 1mm and 2mm below the surface of specimens were detectable. Larger size defects were detectable at greater depth. We also explored an alternative approach to detection of material flaws in PT data cube, which is using neural learning-based approach to blind source separation. Detection of small material defects requires finding features in the data cube which have signal contrast levels approaching sensitivity limit of IR camera. In this study, an optimized Neural Learning based Blind Source Separation (NLBSS) algorithm, including Principal Component Analysis (PCA), and Independent Component Analysis (ICA) is demonstrated to automatically extract principal temporal and spatial features of thermography frames to enhance flaw detection. By using the NLBSS algorithm, material internal defects can be automatically detected. Furthermore, this processing approach compensates for experimental thermal imaging artifacts, such as noise and uneven heating. By merging artificial intelligence with phtotothermics, the NDE system detects internal calibrated defects of various sizes and depths in AM nuclear-grade metallic alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

PORFLOW Implementation of Vadose Zone Conceptual Model for Naval Reactor Component Disposal Areas in the E-Area Low Level Waste Facility Performance Assessment

PORFLOW models have been developed to implement the proposed conceptual models for the two Naval Reactor Component Disposal Areas (NRCDAs), 643-7E and 643-26E, for the purpose of evaluating dose impacts and producing disposal limits for the E-Area Low-Level Facility (LLWF). New NRCDA conceptual models were proposed by Wohlwend and Butcher (2019) for two areas within/adjacent to the E-Area LLWF used as storage/disposal sites for reactor components from the U.S. Navy since 1987. Naval Reactor (NR) waste is comprised of highly radioactive components consisting of activated corrosion-resistant metal alloy contained within welded thick-walled steel casks, and auxiliary equipment primarily contaminated with lower levels of Activated Corrosion Products (ACPs) residing on the metal surfaces and contained within thinner-walled bolted containers.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Comparison of Electron Beam and Laser Beam Powder Bed Fusion Additive Manufacturing Process for High Temperature Turbine Component Materials, Phase II. CRADA Final Report

The evolving additive manufacturing (AM) technology is now at the point where some metallic turbine components are being fabricated for both development and production purposes. The goal of this phase II project is to continue the evaluation of AM Nickel Alloy X fabricated by electron beam (EB) or laser beam (LB) powder bed fusion (PBF) process for gas turbine applications. Microstructure, mechanical and oxidation properties characterization was conducted on test specimens produced with powders of different chemistries within the typical material specification range. Powders with high Silicon (Si) content for the LB-PBF and low Si content for the EB-PBF displayed significant cracking levels in the AM Nickel Alloy X material. Accordingly, optimum fatigue performance would require careful control of powder chemistry, optimization of the fabrication parameters for a given powder and use of hot isostatic pressing (HIP) post treatment. Oxidation testing conducted at 1472°F (800ºC) in air showed that the roughness of the EB-PBF specimens led to an increase in specimen mass change, but overall the AM specimens exhibited oxidation behavior at 1472°F (800ºC) that is appropriate for applications in gas turbine engines. Assessment of the geometric capability of the LB-PBF and EBPBF systems using artifacts representative of turbine component geometries revealed that the LB-PBF process is well-suited for the fabrication of intricate geometries needed for turbine engine fuel injector components, but further process development is required to improve the EB-PBF system feature resolution.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Development of Thermal Tomography Imaging System for In-Service Nondestructive Evaluation of Additively Manufactured Components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. We investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin. MIT research reactor (MITR) has been identified as a representative environment to perform investigation of feasibility of in-service NDE during shutdown. Preliminary study of radiation level in the MITR viewport, with geometric parameters potentially compatible with compact TT system, has been conducted.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Component-In-Grout Model Implementation for the E-Area Low-Level Waste Facility's Performance Assessment

The component-in-grout (CIG) disposal units are below grade earthen trenches that contain grout encapsulated waste components. Components disposed of within the CIG segments consist of large radioactively contaminated equipment and smaller waste forms (e.g., B-25 boxes and SeaLand containers) to fill the space around and above the large equipment. In the 2022 revision of the E-Area Low-Level Waste Facility’s (ELLWF) performance assessment, groundwater radionuclide contaminant transport through the vadose zone will be modeled using the PORFLOW software package for nine existing CIG segments located within the Slit Trench (ST) 23 footprint - no additional CIG segments are planned for at this time. The nine CIG segments have been placed within two of the nominally 20-foot-wide by 656-foot-long ST segments and are surrounded by no less than 1 foot of grout on all sides and up to 4 feet of backfill material. The two most recently placed CIG segments have an additional reinforced concrete mat to improve structural stability.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Performance of Compact Pulsed Thermal Imaging System for In-Service Applications. Pulsed thermal tomography nondestructive examination of additively manufactured reactor materials and components

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to creep in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures nondestructively. Pulsed Thermography (PT) imaging provides a capability for non-destructive evaluation (NDE) of sub-surface defects in arbitrary size structures. The PT method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PT method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. The data cube of PT measurements consists of surface temperature taken at sequential time intervals T(x,y,t). Material defects can be detected either by analyzing the thermograms T(x,y,t) data cube, or by using thermal tomography (TT) algorithm to obtain 3D spatial reconstruction of thermal effusivity e(x,y,z). To reduce the cost and enable in-service NDE in spatially constrained environment, it is highly desirable to develop PT with compact and inexpensive IR camera. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact PT system can also be used for in-service nondestructive evaluation (NDE) applications. However, data cube obtained with PT based on compact IR camera suffers from strong thermal noises and loss of features due to relatively low sampling rate. In this report we describe two unsupervised machine learning (ML) algorithms for enhancement of PT images obtained with compact IR camera. In one approach, we introduce Sparse Coding Discrete Cosine Transform (SC/DCT) algorithm to remove additive white Gaussian noise (AWGN) from spatial thermal effusivity reconstructions. In another approach we introduce a Spatial Temporal Denoised Thermal Source Separation (STDTSS) ML algorithm to process thermograms. The STDTSS algorithm consists of spatial and temporal denoising using Gaussian and Savitzky–Golay filtering, followed by the matrix decomposition using Principal Component Analysis (PCA), and Independent Component Analysis (ICA) to automatically detect flaws. In the work described in this report, we constructed a compact PT system using a relatively small and low-cost FLIR A65 camera, consisting on uncooled microbolometer detector. Performance of SC/DCT algorithm was demonstrated on enhancing TT images of Inconel 718 AM plate. Performance of the STDTSS methods was investigated using thermography data obtained from imaging stainless steel 316L specimens produced with LPBF method with imprinted calibrated porosity defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Large-Scale, GPU-Enhanced DFTB Approaches for Probing Multi-Component Alloys

The major goals of the project are to develop and apply GPU-enhanced density functional theory tight binding (DFTB) calculations for efficient simulations of structural materials of alloy systems. The figure below depicts the GPU algorithmic developments on the left that will be carried out, and the solid-state structures on the right are representative of the complex alloys that can be computed with the GPU-enhanced DFTB approach. The methodology and tools developed in this project encompass accurate intermolecular potentials and GPU enhancements to the density functional tight binding (DFTB) approach for high-throughput ab initio molecular dynamics calculations of multi-component alloys at elevated temperatures. While classical molecular dynamics can handle hundreds of thousands of atoms, it cannot provide a first-principles based description of large, multi-component alloys at the predictive quantum level. At the other extreme, conventional Kohn-Sham DFT methods can probe the true quantum nature of chemical systems; however, these methods cannot tackle the large sizes relevant to these multi-component systems. The DFTB-based ab initio molecular dynamics approach (coupled with our in-house GPU capabilities for enhanced speed) used in this project provides a viable approach for probing these large systems at a quantum level of detail that is significantly faster than current first-principle methods Collectively, the capabilities developed in this project directly respond to DOE HBCU-OMI, AOI 2-1 initiatives by (1) enabling accurate and efficient predictions and (2) bringing a fundamental understanding of structural interactions in these complex systems at elevated temperatures.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Minimizing Cr-Evaporation from Balance Of Plant Components By Utilizing Cost-Effective Alumina-Forming Austenitic Steels

A solid oxide fuel cell (SOFC) is a clean and efficient energy conversion device. The development of intermediate-temperature SOFCs has made it preferable to use metallic interconnects (MICs) to greatly reduce the cost and significantly increase the efficiency compared to ceramic interconnect materials. However, gaseous chromium species will evaporate from the chromium-containing layer formed on the surface of commonly used MICs and balance of plant (BoP) components. Volatile chromium species have been shown to form solid deposits which poison the cathodes of SOFCs, causing drastic cell performance degradation and thereby limiting commercialization. In order to alleviate the Cr poisoning and achieve long-term high performance of SOFC stacks, various Al 2 O 3 -forming austenitic (AFA) stainless steels applied at different temperatures are evaluated in this project. Based on our Phase I results (500 h operation), it is shown that on the AFAs, an alumina-based protective layer forms under high temperature that is invulnerable to water vapor effects and suppresses the diffusion of chromium and manganese which can prevent the generation of spinels on the alloy surface. Therefore, 310S, OC4 and OC5 at 800 °C and 625, OC11 and OC11LZ at 900 °C are selected to be tested in the Phase II long-term operation. From the results, we find that besides the lower Cr evaporation rates and better oxidation resistance of AFAs than benchmark alloys after short-term (500 h) operation, AFAs also possess the sturdy and compact alumina layer after a long-term operation (5000 h). A protective oxide layer is of great importance for the long-term high-temperature operation of structural materials. The high-temperature oxidation behavior of AFAs and commercial 310S and 625 alloys in Air + 10% H 2 O at 800 °C and 900 °C is systematically investigated. Severe breakaway oxidation and minor spallation are observed for the 310S and 625 after the long-term operation, while the AFAs show high oxidation resistance. It is found that the formation of a continuous alumina layer could greatly prevent the volatilization of chromium vapors. In addition, the corresponding evolving models are discussed. Chromium evaporation from BoP components in high-temperature environment could severely deteriorate the electrochemical performance of SOFC. Several methods were applied to evaluate the Cr evaporation rates of BoP after 500 h exposure at 800 °C to 900 °C in air with 10% H 2 O. An optimal method was designed to exclude the effect of silicon (Si) deposits from quartz tube and sodium (Na) deposits from the sodium carbonate on the oxidation process and the chemical interaction between Cr gaseous species and alumina tube which could provide further quantitative correlation of the evaporated Cr species quantities and degradation rates of SOFC. Based on the great performance of AFAs after long-term operation, AFAs are assembled with Anode-supported cells (ASC) to investigate the the Cr deposition of anode-supported cell under a constant current density of 0.5 A cm -2 at 800 °C with AFA alloys compared with commercial alloys. In addition, the anodic and cathodic processes are deconvoluted by distribution of relaxation times (DRT) method which are comprehensively discussed. It is found out that the voltage exhibited a slight decrease of 5.09 % and 1.54 % in the presence of OC11 and OC11LZA alloy, respectively. However, a considerable decrease of 22.14 % and 12.06 % was determined in the presence of 310S and 625 alloy, respectively. AFAs possessing the low-cost, low Cr evaporation rates and the high oxidation resistance will make it of great potential to replace the existing BoP components.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Real-Time Health Monitoring for Gas Turbine Components Using Online Learning and High-Dimensional Data

Capital-intensive turbomachinery, such as gas turbines and combined cycle plants, are constantly being monitored for performance anomalies, faults, and physical degradation. Although these power-generating assets are equipped with hundreds of sensors, existing monitoring tools can only handle moderate-sized data. As a result, only a handful of aggregate metrics are used to monitor machine health. At the same time, developing advanced tools suitable for large datasets have been restricted by the lack of appropriate data. The objective of this proposal was to demonstrate a Big Data analytics framework for fault detection and diagnosis in gas turbine applications. We develop a predictive analytics framework methodology guided by these experimental data, industrial data from our collaborators, and physics-based models with engineering domain knowledge. Our analytics framework consists of four key components (1) a data curation process that addresses data storage, data quality assessments, and integrity checks, (2) a feature engineering component that utilizes statistical methods and transformation algorithms guided by physics-based models to extract high-fidelity fault features that can be leveraged for fault detection and classifying fault severities, (3) a Machine Learning-based fault detection and diagnostics algorithms for detecting operational and hardware faults in the combustion and the turbines section. We utilize two industry-class gas turbine component test rigs to generate first of its kind data for critical gas turbine faults with varying severity levels. Advanced gas turbine test facilities will be interrogated using state-of-the-art instrumentation techniques to build fault signatures and data trends for key combustor and turbine faults. Data generated from a combustor test rig (Georgia Tech) and a turbine test rig (Penn State) during both normal operation and with seeded faults serve as the basis for the Big Data sets. The test conditions in the two test facilities include common, critical events that occur in the operation. Utilizing the combustor test rig, we examine two common combustor faults: lean blowout and centerbody degradation. For the turbine section we develop analytic models for monitoring cooling faults in the gas turbine

03 NATURAL GAS↗