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DOE OSTI2019

Characterizing The Mechanical Properties of Polyurethane Foams

The purpose is to determine the mechanical properties of polyurethane foams with the intent of using PU foams to fill large void asymmetrical volumes like a glovebox to fixate transferable radiological material. Testing the resiliency of foam technologies when exposed to physicals stressors will be done. Six COTS PU foams considered will be fabricated and tested (iT 7, iT 8, iT 14, iT 23, 3M Fire Barrier, and Hilti) with and without additives at 12.5% wt (Bi, WO{sub 3}, and Na{sub 2}WO{sub 3}). Polyurethanes (PU) are a special class of polymeric materials that have great potential in many applications. Used in automotive, biomedical, construction, and textiles industries. Sought after due to its versatility and superior properties. PU foams have become one of the most prominent PU-based products. Bench-scale testing by SRNL and FIU-ARC confirmed PU foam technology's superior capabilities: Cured in various and desired volumes; No samples generated heat above 90 deg. C during curing reaction; Incorporation of additives (Bi, WO{sub 3}, BiO{sub 3}, Na{sub 2}WO{sub 3}) led to the following shielding: 98% of Am-241, 16% of Cs-137, 9.5% of Co-60. Proved foams' resistance to thermal stressors: Foams lasted 2 hours of direct flame; Excellent thermal insulation; Maintained structural integrity; No smoke or flame propagation. Experiment 1: A tensile tester (MTS Criterion Series 43) will be utilize to evaluate various properties of different PU rigid and flexible foams with and without additives (at 12.5% wt) under tension at 1 mm/s. Experiment 2: A thermogravimetric analysis (TGA) and Dynamic Mechanical Analyzer (DMA) will be employed to determine PU foams' breakdown of physical properties while under a constant heat rate (10 C/min) and strain rate (1%) under a period of time. Foams with additives showed an increase in stiffness and durability during tensile testing with WO{sub 3} producing the best results for Foam iT 7. All the other foam samples showed similar trends. Glass transition temperature (Tg) range for Foam iT 7 with Na{sub 2}WO{sub 3} ranged from 120-150 C while Foam iT 7 blank Tg range was from 90-110 C with a difference of about 30 C showing improvement with addition of additives.

36 MATERIALS SCIENCE↗

NASA NTRS1971

Evaluation of some candidate materials for automobile thermal reactors in engine-dynamometer screening tests

Fourteen materials were evaluated in engine screening tests on full-size thermal reactors for automobile engine pollution control systems. Cyclic test-stand engine operation provided 2 hours at 1040 C and a 20-minute air-cool to 70 C each test cycle. Each reactor material was exposed to 83 cycles in 200 hours of engine testing. On the basis of resistance to oxidation and distortion, the best materials included two ferritic iron alloys (Ge 1541 and Armco 18S/R), several commercial oxidation-resistant coatings on AlSl 651 (19-9 DL), and possibly uncoated AISI 310. The best commercial coatings were Cr-Al, Ni-Cr, and a glass ceramic.

Oldrieve, R. E.↗

NASA NTRS1980

Design, durability and low cost processing technology for composite fan exit guide vanes

A program was conducted to design, fabricate and test a durable, low cost, lightweight composite fan exit guide vane for high bypass ratio gas turbine engine application. Eight candidate material/design combinations were evaluated by NASTRAN finite element analysis. Four of these candidate systems were selected for composite vane fabrication by two vendors. A core and shell vane design was chosen in which the unidirectional graphite core fiber was the same for all candidates. The shell material, fiber orientation and ply configuration were varied. Material tests were performed on raw material and composite specimens to establish specification requirements. Composite vanes were nondestructively inspected and subsequently fatigue tested in both dry and 'wet' conditions. The program provided relevant data with respect to design analysis, materials properties, inspection standards, improved durability, weight benefits and part price of the composite fan exit guide vane.

Blecherman, S. S.↗

DOE OSTI2016

Applications of Transient Grating Spectroscopy to Radiation Materials Science

Radiation damage is an inherently multi-scale phenomenon, with much of the key material evolution occurring at the mesoscale. Current techniques for the direct interrogation of material property changes due to irradiation either function with very small volumes, such as in-situ TEM, cannot cover the full range of defect populations produced, such as in positron annihilation spectroscopy, or requires destruction of the test material, such as in standard or micromechanical testing. In addition, the ultimate quantities of interest to radiation materials scientists are the changes in key material properties with irradiation. These include stiffness, ductility, and thermal conductivity for structural materials, and optical properties such as index of refraction or changes in transmittance spectra for optically active materials. The latter of these are often correlated directly to stress- or thermally-induced changes, themselves a function of the specific defect populations responsible for their change. The rapid study of such a mesoscale phenomenon requires an inherently mesoscale technique, where multiple quantities of interest can be accurately measured in very short times. Determining the sensitivity of any technique with known certainly is of critical importance to qualifying a new technique to measure in-situ material property changes during irradiation. In this paper, we present the new applicability of an existing technique, known as transient grating (TG) spectroscopy, to rapidly and accurately study key problems in radiation materials science. Results quantifying the absolute sensitivity of the technique are presented, alongside molecular dynamics (MD) simulations of the TG spectroscopy process to gauge direct agreement between theory, simulation, and experiment. An example problem of interest is demonstrated as an illustration of what is possible, showing elastic and thermal changes in irradiated silicon carbide (SiC) films. Finally, future work to quantify the effects of experimentally-simulated radiation defects is proposed, in support of building a database to use TG spectroscopy to deconvolve irradiated material property changes in-situ in terms of the defect populations responsible for their evolution. The application of the TG spectroscopy technique to in-situ radiation materials science has the potential to answer long-standing questions in the field, relating to ion beam rastering, the onset of void swelling, and direct measurement of radiation-created point defect concentrations. Before it can do so, the technique must carefully be analyzed and tuned to increase its sensitivity, the certainty of its results, and the ability to predict radiation-induced changes by simulations must be developed. Making such measurements in-situ with the aid of predictive MD simulations has the potential to elucidate mechanisms of radiation damage accumulation, as well as more rapidly qualify radiation-resistant alloys for service in nuclear systems. Work is underway to build this database of experimentally-simulated radiation-produced defects, which will be combined and compared with actual irradiated materials for eventual in-situ deconvolution of the TG signal into the defect populations responsible for irradiation-induced microstructural change. (authors)

36 MATERIALS SCIENCE↗

NASA NTRS2016

Thermal Testing of Ablators in the NASA Johnson Space Center Radiant Heat Test Facility

A spacecraft's thermal protection system (TPS) is required to survive the harsh environment experienced during reentry. Accurate thermal modeling of the TPS is required to since uncertainties in the thermal response result in higher design margins and an increase in mass. The Radiant Heat Test Facility (RHTF) located at the NASA Johnson Space Center (JSC) replicates the reentry temperatures and pressures on system level full scale TPS test models for the validation of thermal math models. Reusable TPS, i.e. tile or reinforced carbon-carbon (RCC), have been the primary materials tested in the past. However, current capsule designs for MPCV and commercial programs have required the use of an ablator TPS. The RHTF has successfully completed a pathfinder program on avcoat ablator material to demonstrate the feasibility of ablator testing. The test results and corresponding ablation analysis results are presented in this paper.

Del Papa, Steven↗

NASA NTRS2008

High Performance COPVs for In-Space Storage of High Pressure Cryogenic Fuels

Polymeric composite overwrapped pressure vessels (COPVs) provide an attractive material system to support developing commercial launch business and alternate fuel ventures. However to be able to design with these materials, the mechanical behavior of the materials must be understood with regards to processing, performance, damage tolerance, and environment. For the storage of cryogenic propellants, it is important to evaluate the materials performance and impact damage resistance at cryogenic temperatures in order to minimize weight and to ensure safety and reliability. As part of this study, material tests of candidate fiber and resin systems were used as the basis for the selection of the material combinations for evaluation in a COPV at cryogenic conditions. This comprehensive approach has also been expanded to address issues with impact damage tolerance and material degradation due to environmental factors. KEY WORDS: Cryogenic testing, evaluation and applications for pressure vessels, COPVs, tanks, or storage vessels.

Schneider, Judy↗

DOE OSTI2024

Characterization of Intrinsic Fiber Optic Temperature Sensors by In-core and Furnace Testing

Increased research and development in nuclear technology has raised the demand for novel sensors and instrumentation to meet data objectives, and survive in different conditions and environments, beyond conventional light water reactor (LWR) environments. Expediting the deployment of advanced nuclear technologies by developing, demonstrating, and qualifying advanced reactor fuel forms necessitates a deeper understanding of how irradiation affects fuels and materials' performance. To achieve a more comprehensive understanding of fuels and materials performance, researchers require more specialized experiments and measurements. The demand for innovative sensors to support nuclear fuel development arises from the complexity of materials' behavior under irradiation and the challenges of deploying instrumentation in Material Test Reactors (MTRs) for irradiation tests. Additionally, measurements of material properties require integrated measurement systems to characterize thermal properties, mechanical properties, chemistry, and microstructure [1]. Among the potential measurement techniques, optical fiber-based sensors have been identified as potential sensors to measure different physical phenomena such as temperature, strain, pressure, and fluid level. Optical fiber sensors have the capability to provide multi-sensing and multiplexing instrumentation, allowing the measurement of different physical parameters within a single sensor configuration, and transmitting data collected at multiple locations through a single fiber. They offer immunity to electromagnetic interference, electrical passivity, compatibility with various sensing methodologies, and cost-effectiveness. Beyond their widespread use in telecommunications, silica fiber-based instruments are utilized in industrial applications, even at temperatures reaching 300?400°C, such as distributed temperature sensing in oil and gas recovery. The Department of Energy (DOE) is interested in using fiber optics to support fuel cycle development [2]. Fiber optics are an excellent candidate for harsh environment sensing, including sensing at very high temperatures (1900oC for sapphire optical fibers). Distributed fiber optic sensing has been deployed in other harsh environments like coal gasification plants [3]. Distributed strain sensing, which operates similarly to distributed temperature sensing, has been deployed to monitor underground mines and fibers have been imbedded in soil to monitor sink-hole development [4][5]. The application of fiber optic sensors to advanced reactor development is a promising area of research.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Leveraging the High Flux Isotope Reactor for nuclear fuel development: a review of experiments, facilities, and capabilities

Materials testing reactors (MTRs) have been used to develop in-core nuclear fuels and materials since the outset of the nuclear power industry. However, the closure of prominent MTRs worldwide and protracted construction timelines for new facilities have increased reliance on existing infrastructure for near-term irradiation testing needs. One facility that can support these needs is the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. HFIR boasts the highest steady-state neutron flux in the Western Hemisphere and, among other roles, has been used to rapidly administer high fluences on fuels and materials for fission and fusion reactor applications. This paper reviews HFIR facilities and infrastructure, fuel-bearing irradiation experiments conducted in HFIR, and select nonfueled experiments that demonstrate advanced techniques transferable to fuels experiments. Collectively, these examples underscore HFIR's potential role as a nuclear fuels testbed supporting both the existing reactor fleet and advanced reactor fuel development.

Fuel qualification↗

DOE OSTI2015

Atomic-scale mechanisms of helium bubble hardening in iron

Generation of helium due to (n,α) transmutation reactions changes the response of structural materials to neutron irradiation. The whole process of radiation damage evolution is affected by He accumulation and leads to significant changes in the material s properties. A population of nanometric He-filled bubbles affects mechanical properties and the impact can be quite significant because of their high density. Understanding how these basic mechanisms affect mechanical properties is necessary for predicting radiation effects. In this paper we present an extensive study of the interactions between a moving edge dislocation and bubbles using atomic-scale modeling. We focus on the effect of He bubble size and He concentration inside bubbles. Thus, we found that ability of bubbles to act as an obstacle to dislocation motion is close to that of voids when the He-to-vacancy ratio is in the range from 0 to 1. A few simulations made at higher He contents demonstrated that the interaction mechanism is changed for over-pressurized bubbles and they become weaker obstacles. The results are discussed in light of post-irradiation materials testing.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Advanced Natural Gas Reciprocating Engine(s)

Energy independence and fuel savings are hallmarks of the nation’s energy strategy. The advancement of natural gas reciprocating engine power generation technology is critical to the nation’s future. A new engine platform that meets the efficiency, emissions, fuel flexibility, cost and reliability/maintainability targets will enable American manufacturers to have highly competitive products that provide substantial environmental and economic benefits in the US and in international markets. Along with Cummins and Waukesha, Caterpillar participated in a multiyear cooperative agreement with the Department of Energy to create a 50% efficiency natural gas powered reciprocating engine system with a 95% reduction in NOx emissions by the year 2013. This platform developed under this agreement will be a significant contributor to the US energy strategy and will enable gas engine technology to remain a highly competitive choice, meeting customer cost of electricity targets, and regulatory environmental standard. Engine development under the Advanced Reciprocating Engine System (ARES) program was divided into phases, with the ultimate goal being approached in a series of incremental steps. This incremental approach would promote the commercialization of ARES technologies as soon as they emerged from development and would provide a technical and commercial foundation of later-developing technologies. Demonstrations of the Phase I and Phase II technology were completed in 2004 and 2008, respectively. Program tasks in Phase III included component and system development and testing from 2009-2012. Two advanced ignition technology evaluations were investigated under the ARES program: laser ignition and distributed ignition (DIGN). In collaboration with Colorado State University (CSU), a laser ignition system was developed to provide ignition at lean burn and high boost conditions. Much work has been performed in Caterpillar’s DIGN program under the ARES program. This work has consisted of both modeling and single cylinder engine experiments to quantify DIGN performance. The air handling systems of natural gas engines dissipate a percentage of available energy as a result of both flow losses and turbomachinery inefficiencies. An analytical study was initiated to increase compressor efficiency by employing a 2-stage inter-cooled compressor. Caterpillar also studied a turbo-compound system that employs a power turbine to recover energy from the exhaust gases for improved engine efficiency. Several other component and system investigations were undertaken during the final phase of the program to reach the ultimate ARES goals. An intake valve actuation system was developed and tested to improve engine efficiency, durability and load acceptance. Analytical modeling and materials testing were performed to evaluate the performance of steel pistons and compacted graphite iron cylinder head. Effort was made to improve the detonation sensing system by studying and comparing the performance of different pressure sensors. To reduce unburned hydrocarbon emissions, different camshafts were designed and built to investigate the effect of exhaust valve opening timing and value overlap. 1-D & 3-D coupled simulation was used to study intake and exhaust manifold dynamics with the goal of reducing load in-balance between cylinders. Selective catalytic reduction with on-board reductant generation to reduce NOx emissions was also engine tested. An effective mean to successfully deploy ARES technologies into the energy markets is to deploy demonstration projects in the field. In 2010, NETL and Caterpillar agreed to include a new “opportunity fuel” deliverable and two field demonstrations in the ARES program. An Organic Rankine Cycle system was designed with production intent incorporating lessons learned from the Phase II demonstration. Unfortunately, business conditions caused Caterpillar to cancel this demonstration in 2011. Nonetheless, Caterpillar partnered with a local dealer to deploy an ARES class engine using syngas from a biomass gasifier as the DE-FC26-01CH11079 primary combustion fuel in Gleason, TN. Upon the successful start-up and commissioning of the demonstration unit, ownership of the system was transferred to the dealer. In order to further our understanding of syngas combustion, a fundamental combustion study on syngas combustion at high pressure and lean condition was conducted through the collaboration with University of Southern California. A Methane program was also developed to rate engine performance for various compositions of syngas using empirical data obtained at CSU. While much work remains in terms of extending and integrating these developments into commercial products, it is evident that engine manufacturers on our own or through private consortium efforts could not have overcome the financial hurdles to drive these improvements into reciprocating engine and system capabilities, helping maintain the natural gas reciprocating engine power generation technology as a strong option for electric power markets, both in the United States and worldwide.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2015

Structural Testing of the Blade Reliability Collaborative Effect of Defect Wind Turbine Blades

Two 8.3-meter (m) wind turbine blades intentionally constructed with manufacturing flaws were tested to failure at the National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory (NREL) south of Boulder, Colorado. Two blades were tested; one blade was manufactured with a fiberglass spar cap and the second blade was manufactured with a carbon fiber spar cap. Test loading primarily consisted of flap fatigue loading of the blades, with one quasi-static ultimate load case applied to the carbon fiber spar cap blade. Results of the test program were intended to provide the full-scale test data needed for validation of model and coupon test results of the effect of defects in wind turbine blade composite materials. Testing was part of the Blade Reliability Collaborative (BRC) led by Sandia National Laboratories (SNL). The BRC seeks to develop a deeper understanding of the causes of unexpected blade failures (Paquette 2012), and to develop methods to enable blades to survive to their expected operational lifetime. Recent work in the BRC includes examining and characterizing flaws and defects known to exist in wind turbine blades from manufacturing processes (Riddle et al. 2011). Recent results from reliability databases show that wind turbine rotor blades continue to be a leading contributor to turbine downtime (Paquette 2012).

17 WIND ENERGY↗

NASA NTRS1971

Materials investigation and tests for the development of space compatible electrical connectors

A molding study of compounds based on copolymers of highly fluorinated olefins and of flame retardant silicone is reported. Both single cavity and four cavity molds having size 22 and 24 holes with three webs in each hole were used. Also covered are dielectric strength, arc resistance, Bashore rebound, and maintenance aging tests on the various materials that have been successfully molded.

Pomeroy, C.↗

NASA NTRS1981

Investigation of creep by use of closed loop servo-hydraulic test system

Creep tests were conducted by means of a closed loop servo-controlled materials test system. These tests are different from the conventional creep tests in that the strain history prior to creep may be carefully monitored. Tests were performed for aluminum alloy 6061-0 at 150 C and monitored by a PDP 11/04 minicomputer at a preset constant plastic-strain rate prehistory. The results show that the plastic-strain rate prior to creep plays a significant role in creep behavior. The endochronic theory of viscoplasticity was applied to describe the observed creep curves. The concepts of intrinsic time and strain rate sensitivity function are employed and modified according to the present observation.

Wu, H. C.↗

NASA NTRS1990

Propulsion system filter sizing considerations for the Galileo spacecraft

Filtration capacity of the Galileo propulsion system has been investigated. Ground testing of flight spare components has been conducted to determine the representative number and size distribution of particulate matter collected in flow tests. For these tests and for filter qualification tests, a number of effects were examined. The influence of gravitational particle settling on ground test results vs the flight environment was considered. Centrifugal effects inherent in the test apparatus and/or the propulsion system could have an influence. Variability among particle sizing techniques was explored. The influence of size distribution, particle shape, and density in the choice of a particulate test material was studied. Characteristics for AC Coarse Dust (an industry standard filter test media), microscopic polymer beads, and aluminum oxide particulate test matter are listed. Filtration tests were conducted using AC Coarse Dust and mixtures containing components of AC Coarse Dust. These results are expected to be useful data for filter sizing of future spacecraft.

Jan, Darrell L.↗

NASA NTRS1993

Development of thin film thermocouples on ceramic materials for advanced propulsion system applications

Thin film thermocouples were developed for use on metal parts in jet engines to 1000 C. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hr or more up to temperatures of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, Raymond↗

NASA NTRS1992

Development of Thin Film Thermocouples on Ceramic Materials for Advanced Propulsion System Applications

Thin film thermocouples have been developed for use on metal parts in jet engines to 1000 c. However, advanced propulsion systems are being developed that will use ceramic materials and reach higher temperatures. The purpose of this work is to develop thin film thermocouples for use on ceramic materials. The new thin film thermocouples are Pt13Rh/Pt fabricated by the sputtering process. Lead wires are attached using the parallel-gap welding process. The ceramic materials tested are silicon nitride, silicon carbide, aluminum oxide, and mullite. Both steady state and thermal cycling furnace tests were performed in the temperature range to 1500 C. High-heating-rate tests were performed in an arc lamp heat-flux-calibration facility. The fabrication of the thin film thermocouples is described. The thin film thermocouple output was compared to a reference wire thermocouple. Drift of the thin film thermocouples was determined, and causes of drift are discussed. The results of high heating rate tests up to 2500 C/sec are presented. The stability of the ceramic materials is examined. It is concluded that Pt13Rh/Pt thin film thermocouples are capable of meeting lifetime goals of 50 hours or more up to temperature of 1500 C depending on the stability of the particular ceramic substrate.

Holanda, R.↗

NASA NTRSDate not supplied

Obtaining cryogenic molecular transport data for analysis

The James Webb Space Telescope (JWST) has a primary mirror, made of 18 segments, and a secondary mirror (SM) that are used to direct the light of desired targets. While on orbit, the secondary mirror assembly (SMA) was stowed for approximately 10 days and was subject to molecular contamination outgassing from the cavity of the secondary mirror support structure (SMSS) in-board hinge (IBH) which contains cables, motors, resolvers, and coatings. The main concern during this period before SMA deployment is the accumulation of ice due to the lack of a heater on the SMA. The temperature differentials between the IBH surfaces and SMA could cause redistribution of contaminants. To address this concern, single layer insulation (SLI) was used to create adequate venting and path redirection of outgassing from the IBH. Two separate thermal vacuum tests were performed to quantify this contamination: one Z307 ASTM E 1559 materials test of the radiator paint used on the motor of the IBH and a separate test on a primary mirror backplane assembly (PMBA) qualification engineering test unit (ETU) of the IBH. These tests approximately followed the predicted SMA pre-deployment thermal environment. To quantify source rates in case of a leak, the motor and resolver sides were separated and quartz crystal microbalances (QCM) were used to measure the deposition of water. The SLI redesign and implementation and outgassing measurements to understand leak effects from the IBH were essential to mitigate the deposition of contamination on the SMA.

James Webb Space Telescope, contamination, cleanro↗

NASA NTRSDate not supplied

Obtaining Cryogenic Molecular Transport Data for Analysis

James Webb Space Telescope↗