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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 OSTI2021

Understanding fission gas bubble distribution, lanthanide transportation, and thermal conductivity degradation in neutron-irradiated α-U using machine learning

U—10Zr based metallic nuclear fuel is the leading candidate for next-generation sodium-cooled fast reactors in the United States. US research reactors have used and tested this fuel type since the 1960s and accumulated considerable experience and knowledge about the fuel performance. Most of the knowledge, however, remains empirical. The lack of mechanistic understanding of fuel performance puts a large burden on proof through experimental verification for the qualification of U—10Zr fuel for commercial use. Further, this paper proposes an image data-driven machine learning approach, coupled with domain knowledge provided by advanced post irradiation examination, to provide unprecedented quantified insights into the morphology, size, density and the connectivity of fission gas bubbles and their effects on the fission product transportation and thermal conductivity. Specifically, we developed a method to automatically detect, extract statistics, and classify ~19,000 fission gas bubbles into different categories, and quantitatively link the data to lanthanide transportation through connected bubbles and degradation of thermal conductivity along the radial temperature gradient in a neutron irradiated U—10Zr annular fuel. Results indicate the approach can be modified to study other irradiation effects, such as secondary phase redistribution and gaseous fuel swelling in other irradiated nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1996

Performance Improvement Through Indexing of Turbine Airfoils: Numerical Simulation - Part 2

An experimental/analytical study has been conducted to determine the performance improvements achievable by circumferentially indexing succeeding rows of turbine stator airfoils. A series of tests was conducted to experimentally investigate stator wake clocking effects on the performance of the space shuttle main engine (SSME) alternate turbopump development (ATD) fuel turbine test article (TTA). The results from this study indicate that significant increases in stage efficiency can be attained through application of this airfoil clocking concept. Details of the experiment and its results are documented in part 1 of this paper. In order to gain insight into the mechanisms of the performance improvement, extensive computational fluid dynamics (CFD) simulations were executed. The subject of the present paper is the initial results from the CFD investigation of the configurations and conditions detailed in part 1 of the paper. To characterize the aerodynamic environments in the experimental test series, two-dimensional (2D), time accurate, multistage, viscous analyses were performed at the TTA midspan. Computational analyses for five different circumferential positions of the first stage stator have been completed. Details of the computational procedure and the results are presented. The analytical results verify the experimentally demonstrated performance improvement and are compared with data whenever possible. Predictions of time-averaged turbine efficiencies as well as gas conditions throughout the flow field are presented. An initial understanding of the turbine performance improvement mechanism based on the results from this investigation is described.

Griffin, Lisa W.↗
NASA NTRS2012

Effect of Aromatic Concentration of a Fischer-Tropsch Fuel on Thermal Stability

Fischer-Tropsch (F-T) jet fuel composition differs from petroleum-based, conventional commercial jet fuel because of differences in feedstock and production methodology. Fischer­ Tropsch fuel typically has a lower aromatic and sulfur content and consists primarily of iso and normal parafins. The ASTM D3241 specification for Jet Fuel Thermal Oxidation Test (JFTOT) break point testing method was used to test the breakpoint of a baseline commercial grade F-T jet fuel, and various blends of this F-T fuel with an aromatic solution. The goal of this research is to determine the effect of aromatic content on the thermal stability of Fischer-Tropsch fuel. The testing completed in this report was supported by the NASA Fundamental Aeronautics Subsonics Fixed Wing Project.

Klettlinger, Jennifer Lindsey Suder↗
DOE OSTI2020

X-ray and gamma-ray tomographic imaging of fuel relocation inside sodium fast reactor test assemblies during severe accidents

The present work reports on x-ray and gamma-ray high-spatial resolution computerized tomography measurements of the Pin Bundle Metallic Fuel Relocation (PBR) assemblies tested in the Metallic Uranium Safety Experiment (MUSE) facility at Argonne National Lab (ANL). The aim of the study was to characterize fuel relocation structures that develop during severe core accidents pertaining to SFR assemblies; these include but are not limited to advanced core disruption recreated in the PBR-1 assembly, and cladding breach recreated in the PBR-2 assembly. We report the x-ray tomography measurements were able to resolve small quantities of relocation fuel; with increased presence of relocation fuel, the x-ray 1measurements spatially mapped the material but could not resolve the inner regions of these. The gamma-tomography measurements showed improved results, resolving the relocation structures in great detail. The upper plenum of the PBR-1 assembly where the molten uranium was initially inserted presented high structural damage, reflected by the partial and complete disintegration of the central rods. Relocation fuel filled the subchannels, adhering to surviving cladding walls and the assembly casing. In the lower portion of the measured section, the tomogram degrades due to photon starvation effects hinting at the increased amount of relocation fuel potentially plugging the assembly; flow blockage in this section was difficult to determine due to the tomogram’s degradation from photon starvation. Small fragments were observed further down the assembly, dislodged from the initial insertion of the molten material. This section was used as an unperturbed assembly reference, with a calculated blockage of less than 1% from the present fragments. The PBR-2 assembly was characterized by columnar relocation structures propagating through the subchannels. Three of the relocation structures were captured in the measured section, with evidence of cross migration on to adjacent subchannels. The measured section in this assembly captures the leading edge of two structures. The calculated flow blockage was 16% in the planes where the three relocation structures are present, but this quickly decreases to approximately 5% past the leading edge of two of the structures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Spark Plasma Sintering (SPS) Update for the Fuel Conversion Effort at the Transient Reactor Test Facility

Over the lifetime of the Transient Reactor Test Facility (TREAT) reactor from 1959 to 1994, a series of historical tests disclosed certain material specific requisites for irradiation testing variables resulted in negligible structural damage after exposure to the reactor and multiple experiments. Comparable fuel design, material testing, and qualifications needs to occur for the high-enriched uranium (HEU) to low enriched uranium (LEU) fuel conversion (<20% U235) of TREAT. This includes, retaining a uniform precipitate dispersion of fueled UO2 micron-size particles throughout a graphite-moderating matrix, where high-density graphite is in direct contact with the fuel and acts as a moderator. On that note, the design of future LEU reactor TREAT fuel core will consider the relative sizing and spacing of fuel as well as the retention of graphite in accordance with the expected thermal, neutron, and energy portfolio for future conversion. In light of the above, LEU conversion fuel blocks currently being manufactured must undergo critical materials testing, irradiation, and examination to determine effects on the manufactured replacement fuel blocks at the millimeter to sub-micron size scale. Herein, we will report and update the community on value-added studies focusing on spark plasma sintering as an alternative technique to fabricate high density graphite dispersion fuel.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Future Opportunities for LWR Irradiations in US Test Reactors

After several years of relatively low activity in the field of Light Water Reactor (LWR) fuel development, the Department of Energy again began to engage in developing new fuel technologies and irradiation performance data prompted by the Fukushima Daichi nuclear accidents. New competencies for irradiation testing in material test reactors in the United States began to be developed at this time using the Advanced Test Reactor (ATR), High Flux Isotope Reactor (HFIR), Massachusetts Institute of Technology Reactor (MITR), and the Transient Reactor Test Facility (TREAT). Capsules for testing fuel and cladding materials in ATR and HFIR were deployed, a Pressurized Water Reactor (PWR) condition loop for testing fuel rods was established in ATR, cladding corrosion studies were performed using a water loop in MITR, and TREAT pulse testing capabilities were commissioned for fuel rods in water capsules. The more recent and unexpected closure of the Halden Boiling Water Reactor (HBWR) also prompted further investments in Loss of Coolant Accident (LOCA) testing capabilities at TREAT. New configurations of these test devices show further potential in enhanced steam condition control and other investigations are building toward a flowing water loop for testing transient to dryout conditions. The closure of HBWR also prompted a major project currently underway to construct additional water loops in ATR where a novel approach is being pursued to enable Boiling Water Reactor (BWR) conditions. A meaningful collaborative project was awarded to MITR which, amidst an unexpected major overhaul of the reactor, has expanded cladding corrosion test capabilities at MITR. New explorations have led to methods for unique experiments at HFIR including channel box irradiations. New device developments are also bridging toward future potential for instrumented capsule irradiation tests in ATR and HFIR. Finally, a new project referred to as the System Physics Advanced Reactor Critical facility (SPARC) is gaining traction towards a large zero-power reactor able to produce physics validation data for LWR fuel bundle designs with increased enrichment and enhanced absorbers for 24-month operation cycles. This paper provides a brief summary of the status of these irradiation testbed capabilities with an emphasis on current efforts toward future capabilities to obtain new data and maximize the performance potential of LWR fuel technologies.

Woolstenhulme, Nicolas [Idaho National Laboratory ↗
NASA NTRS1983

Automotive Stirling Engine Development Program

Mod I engine testing and test results, the test of a Mod I engine in the United States, Mod I engine characterization and analysis, Mod I Transient Test Bed fuel economy, Mod I-A engine performance are discussed. Stirling engine reference engine manufacturing and reduced size studies, components and subsystems, and the study and test of low-cost casting alloys are also covered. The overall program philosophy is outlined, and data and results are presented.

Nightingale, N.↗
NASA NTRS2020

Simulation of Hydrogen Flow in a Nuclear-Thermal Propulsion Reactor Subsystem: Conjugate Heat Transfer in Surrogate Fuel Elements and Flow Through the Dome Inlet to the Fuel Elements

NASA is performing research related to a Nuclear-Thermal Propulsion (NTP) engine as a step toward future manned missions to Mars. BWX Technologies (BWXT), in conjunction with NASA, is developing the reactor subsystem for that NTP engine design. As a subset of the reactor subsystem, the fuel elements have continued to evolve in design, as well. A set of experiments within the Nuclear Thermal Reactor Element Environmental Simulator at NASA Marshall has been developed to compliment that design process, including a series of surrogate fuel elements. Before the experiments of each surrogate can be completed, they must be deemed safe using structural analysis, which itself requires thermal and conjugate heat transfer analyses of the articles. Therefore, conjugate heat transfer simulations of the hydrogen flow through the test article fuel element surrogates were developed to provide estimates of heating, as well as to provide assessments of the fluid flow through the elements. The set of simulations involved not only the separate test conditions, but also a sensitivity study to estimate the effect of physical parameter uncertainty on the selected quantities of interest. Additionally, the fluid flow through the fore section inner plenum dome to the entrances of the fuel elements, another section of the reactor subsystem still under active development, was simulated and analyzed. The simulations show the extent of non-uniformity in the mass flow distribution across the dome outlets. Furthermore, additional analyses estimate the effects of required flow blockages on the potential development of flow dynamics. These analyses were used in the design cycle to make improvements to the reactor subsystem design.

Kalen E. Braman↗
DOE OSTI2015

Fuel properties to enable lifted-flame combustion

The Fuel Properties to Enable Lifted-Flame Combustion project responded directly to solicitation DE-FOA-0000239 AOI 1A, Fuels and Lubricants for Advanced Combustion Regimes. This subtopic was intended to encompass clean and highly-efficient, liquid-fueled combustion engines to achieve extremely low engine-out nitrogen oxides (NOx) and particulate matter (PM) as a target and similar efficiency as state-of-the-art direct injection diesel engines. The intent of this project was to identify how fuel properties can be used to achieve controllable Leaner Lifted Flame Combustion (LLFC) with low NOx and PM emissions. Specifically, this project was expected to identify and test key fuel properties to enable LLFC and their compatibility with current fuel systems and to enhance combustion models to capture the effect of fuel properties on advanced combustion. Successful demonstration of LLFC may reduce the need for after treatment devices, thereby reducing costs and improving thermal efficiency. The project team consisted of key technical personnel from Ford Motor Company (FMC), the University of Wisconsin-Madison (UW), Sandia National Laboratories (SNL) and Lawrence Livermore National Laboratories (LLNL). Each partner had key roles in achieving project objectives. FMC investigated fuel properties relating to LLFC and sooting tendency. Together, FMC and UW developed and integrated 3D combustion models to capture fuel property combustion effects. FMC used these modeling results to develop a combustion system and define fuel properties to support a single-cylinder demonstration of fuel-enabled LLFC. UW investigated modeling the flame characteristics and emissions behavior of different fuels, including those with different cetane number and oxygen content. SNL led spray combustion experiments to quantify the effect of key fuel properties on combustion characteristics critical for LLFC, as well as single cylinder optical engine experiments to improve fundamental understanding of flame lift-off, generate model validation data, and demonstrate LLFC concurrent with FMC efforts. Additionally, LLNL was added to the project during the second year to develop a detailed kinetic mechanism for a key oxygenate to support CFD modeling. Successful completion of this project allowed the team to enhance fundamental understanding of LLFC, improve the state of current combustion models and increase understanding of desired fuel properties. This knowledge also improves our knowledge of how cost effective and environmentally friendly renewable fuels can assist in helping meet future emission and greenhouse gas regulations.

Kurtz, Eric↗
DOE OSTI2023

Simplifying the Advanced Test Reactor LOWE Element Test Series

The Advanced Test Reactor (ATR) is one of six remaining high performance research reactors in the United States scheduled to be converted from 93% high-enriched uranium (HEU) fuel to 19.75% low-enriched uranium (LEU) fuel as part of the Department of Energy (DOE), National Nuclear Security Administration (NNSA), Office of Material Management and Minimization (MMM) reactor conversion efforts(1). The specific LEU fuel element design for the ATR is called the Low Enriched (LOWE) element. A series of fuel qualification tests are scheduled to occur over the next decade before the ATR is fully converted. In addition to several experiments of demonstration plates, a series of Element Tests (ETs) are planned for conversion, in which full sized LOWE elements are placed in ATR driver positions. The purpose of these ETs was generally to sequentially increase the amount of LEU and core power to full power, therefore creating a representative safety profile in which LEU could operate for the duration of the ATR lifetime. The planned element tests were (2): ET-1: one LOWE element at low power for once cycle ET-2: ~8 LOWE elements at low/medium power for multiple cycles, and ET-3: >8 LOWE elements for a full lobe of elements at high power for multiple cycles. Given recent improvements in modeling fidelity, scheduling considerations, and an opportunity to combine later ETs, the LEU conversion program successfully defined the operational requirements for the “ET-ATR” test, which combines the needed information collected from ET-2 and ET-3 into a single test.

42 ENGINEERING↗
DOE OSTI2024

Expansion of the Fuel Motion Monitoring System

The Idaho National Laboratory (INL) Transient Reactor Test Facility (TREAT) Fuel Motion Monitoring System (FMMS) is a diagnostic tool used to visualize the movement and location of fuel within the nuclear reactor during transient experiments. TREAT is designed to test the behavior of nuclear fuel under accident conditions, such as a rapid power increase. The TREAT FMMS, also referred to as the “hodoscope” because of the system’s massive steel collimator component, is located on the North beam port of the reactor. While the FMMS system is capable of incorporating a total of 360 sensors, initial refurbishment efforts resulted in a array of 96 fast neutron detectors. This initial array was configured to provide a narrow (2 channels) full-length view of experiment vessels with an extended 4-channel–wide region in the center of the array capable of providing a full view of all initially planned experiments. Planning and efforts to expand the FMMS array began immediately following the restart of TREAT. An additional 96 detectors were evaluated, characterized, and prepared for installation at TREAT during the summer of 2018. Unfortunately, funding reductions forced the project towards a 5-year hiatus. In October of 2023 funding from the Department of Energy’s Nuclear Science User Facilities enabled the expansion to recommence. This report serves to document the activities performed to expand the FMMS detector array to 192 channels in order to provide a broader view of the larger and more sophisticated test capsules currently planned for future irradiation in the TREAT reactor. This expansion also included doubling the data acquisition capability, addressing the new heat load on the system, and synchronizing the time for all digital components.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1983

Rheological behavior of FM-9 solutions and correlation with flammability test results and interpretations

The rheological behavior of progressively shear thickening FM-9 solutions, a time-dependent shear thickening material with characteristics of threshold behavior, is investigated as part of a study of the rheological properties of antimisting jet fuel. Flammability test results and test configurations from various sources are evaluated. A correlation is obtained between the rheological behavior and the flammability tests such that, for a given system, such as a fixed solvent system and the FM-9 polymer system, the flammability criterion can be applied to a wide range of concentrations and temperatures.

Peng, S. T. J.↗
DOE OSTI2016

Small Volume Fuel Testers Report

Micro-liter fuel ignition testing (μ-FIT) is based on the premise that characteristics FREI (Flames with Repetitive Extinction and Ignition, i.e. cyclically occurring combustion events within heated capillaries), are linked to fuel properties. In early FY16, proof-of-concept measurements with primary reference fuel (PRF) mixtures, i.e. blends of n-heptane and iso-octane, yielded clear evidence for the feasibility of the approach. Our experiments showed that it is critical to accurately link observed flame positions to local temperatures, which provides information on ignition, extinction and flame propagation, all of which are known to be impacted by fuel properties. In FY16, one major hurdle was uncertainty of temperature calibration, which required significant efforts for corrective action that were not included in the original scope of work. Temperature calibrations are obtained by translating a thermocouple within the capillary in absence of a flame. While measurements have good repeatability when accounting for transient and insertion effects, results from nominally identical thermocouples reveal unacceptable uncertainty (up to ±50K), which is attributed to variations in thermocouple placement and manufacturing tolerances. This issue is currently being resolved by switching to non-intrusive optical temperature measurements. Updates are expected to yield uncertainties of less than ±10K, while also eliminating transient and insertion effects. The experimental work was complemented by computational efforts where it was shown that a simplified Lagrangian zero-D model with detailed kinetics yields fuelspecific differentiation of ignition temperatures for simple fuels that are consistent with experiments. Further, a 2D transient model was implemented in OpenFOAM to investigate combustion behavior of simple fuels at elevated pressure. In an upcoming visit to LLNL, more advanced simulations using LLNL’s computational tools (e.g. zero-RK) are planned, which will yield additional numerical insights on FREI behavior of more realistic spark ignited (SI) engine fuel surrogates. As there is a lag between DOE FY16 and the time frame of the LSU subcontract, it is anticipated that deliverables outlined in the scope of work will be met by the end of the subcontract (January 2017).

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2018

Polyalkylene Glycol (PAG) Based Lubricant for Light & Medium Duty Axles

The axle lubricant (SAE 75W-140) widely used in the market place over the last few years is primarily formulated from polyalpha olefin (PAO) basestock. This investigation focused on polyalkylene glycol (PAG) base stock which is significantly different chemically from PAO and because of their polar nature it is hypothesized that it can adsorb relatively easily on contacting surfaces resulting in significant friction reduction and improve fuel economy. Axle efficiency is generally quite high at high torque range but it could be quite low at low torque range representative of EPA drive cycles. Therefore, this project primarily focus on improving axle efficiency in the low torque range while maintaining all durability attributes. The objective of this project is to develop novel lubricant formulations that are expected to improve the fuel efficiency of light, medium, heavy-duty, and military vehicles by at least 2% over Society of Automotive Engineers (SAE) 75W-140 axle lubricants (improvement based on comparative results from engine dynamometer testing, chassis dynamometer testing or test track, e.g., SAE J1321) without adverse impacts on vehicle performance or durability. The proposed research project followed a structured approach beginning with lubricant formulations by varying base oil chemistry and additive components followed by physical property characterization. Lubricant performance evaluations started with simple laboratory friction, wear, oxidation, and corrosion tests which guided into identification of performance areas requiring improvements. This required an iterative lubricant reformulation. Once a few acceptable formulations were identified, they are evaluated in more complex component tests including ASTM tests (L-37 - load carrying capacity under low speed and high torque, L42 – load carrying properties under high speed and shock loading, L-60 - thermal and oxidative stability, and L-33-1 moisture corrosion resistance). Two issues were observed following L-42 tests; toxicological and foaming. This required reformulation and repeating all ASTM tests. During repeat tests it was observed that some of the additives precipitated out of solution. Since it was discovered quite late in the program, and the time it may need to find a solution to this issue, the team changed direction of the program to switch to use of an oil soluble PAG as a co-basestock (15-30%) with mineral oil used in a commercial formulation (SAE 75W-85). This formulation strategy helped passing all ASTM tests. This was followed by Ford proprietary axle efficiency, gear wear, and chassis roll dynamometer tests for fuel economy evaluations. Axle efficiency was improved up to 7% when a full PAG formulation was used but no such significant improvement was observed with PAG as co-basestock formulation. Chassis roll fuel economy improved by 1.9% with PAG co-basestock formulation (conforming to SAE 75W-85) compared to SAE 75W-140 baseline. However, it was observed that the improvement is mostly due to reduced viscosity of candidate formulation when compared to a full mineral oil based SAE 75W-85 formulation. PAG as co-basestock also exhibited unacceptable wear in proprietary gear wear test. This investigation highlighted challenges with PAG formulations including identification of additive components that stay in PAG solution for intended duration, and meeting component durability requirement.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Advanced Microscopy for Characterization of High Burnup Commercial UO 2 Fuel Before and After LOCA Testing

This report presents the results from the microstructural examination of high burnup UO 2 under pre- and post- loss of coolant accident (LOCA) conditions. The work in this report builds and expands upon work previously conducted on high burnup UO 2 fuel at Oak Ridge National Laboratory (ORNL). This work investigates the microstructural evolution that occurs during steady state irradiation of UO 2 , particularly in high burnup fuel. Several high burnup fuel samples were available from historic fuel shipments to ORNL. Microstructural characterization will aid in understanding why the fuel is susceptible to fuel fragmentation and support future work to investigate the formation mechanisms of certain features that form under irradiation. High burnup UO 2 microstructural data is also needed to improve constitutive models intended to predict high burnup fuel fragmentation (HBFF). This report summarizes the microstructural evaluation of these fuel samples to interpret and analyze high burnup fuel microstructures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Potential Impacts of High-Octane Fuel Introduction in a Naturally Aspirated, Port Fuel-Injected Legacy Vehicle

In recent years there has been an increased interest in raising the octane level of gasoline to enable higher compression ratios (CR) in spark-ignition engines to improve vehicle fuel efficiency. A number of studies have examined opportunities to increase efficiency in future vehicles, but potential impacts on the legacy fleet have not received as much attention. In this study, our effort focused on experimental studies on an engine using high-octane fuels without changing the engine’s CR. Spark timing was advanced until maximum torque was reached or knock was encountered for each engine condition, using each individual fuel to maximize engine efficiency. Knock-limited conditions occurred as the output brake mean effective pressure (BMEP) neared the maximum attainable output at a given engine speed. Increasing research octane numbers generally enabled knock-free operation under a greater number of operating conditions. Vehicle modeling using Autonomie was used to project vehicle energy use, fuel economy, and tailpipe CO 2 emissions for the Urban Dynamometer Driving Schedule (UDDS), the Highway Fuel Economy Test (HWFET), and the US06 cycle. Results show that decreases in energy consumption of up to 2% for a small SUV are possible through the use of a 97 RON fuel compared to a baseline using 91 RON fuel, provided that the formulation of the fuel does not cause unanticipated operational issues such as lower maximum BMEP. Greater improvements using high-octane fuels are possible if the CR is increased, but there is no opportunity to increase the CR in legacy vehicles. Thus, these vehicles realize an improvement from increased octane rating in accordance with their ability to spark advance to take advantage of a fuel with a higher octane rating. For the modeled vehicle, improvements of up to 2% in volumetric fuel economy may be possible through the use of a 97 RON fuel with the largest gains expected on the US06 cycle. Fuel economy impacts are strongly coupled to the heating value of the fuels in addition to changes in engine efficiency. Similarly, decreases in tailpipe CO 2 emissions are also achievable. However, simultaneous improvements in energy consumption, fuel economy, and tailpipe CO 2 emissions are not guaranteed and are dependent upon fuel formulation.

33 ADVANCED PROPULSION SYSTEMS↗