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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 847 records · Page 47

The Power of Priors: Improved Enrichment Safeguards

International safeguards currently rely on material accountancy to verify that declared nuclear material is present and unmodified. Although effective, material accountancy for large bulk facilities can be expensive to implement due to the high precision instrumentation required to meet regulatory targets. Process monitoring has long been considered to improve material accountancy. However, effective integration of process monitoring has been met with mixed results. Given the large successes in other domains, machine learning may present a solution for process monitoring integration. Past work has shown that unsupervised approaches struggle due to measurement error. Although not studied in depth for a safeguards context, supervised approaches often have poor generalization for unseen classes of data (e.g., unseen material loss patterns). This work shows that engineered datasets, when used for training, can improve the generalization of supervised approaches. Further, the underlying models needed to generate these datasets need only accurately model certain high importance features.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Origin and development of ablator for Space Shuttle external tank

The Space Shuttle External Tank (ET) represents the largest element of the Space Shuttle transportation system. The ET is the fuel tank which contains cryogenic propellants, including liquid oxygen and liquid hydrogen. The task of providing a suitable Thermal Protection System (TPS) which is mass producible for the ET represented a challenge for the aerospace industry. The difficulties were compounded by stringent insulation and ablation requirements for the materials to maintain their integrity over a wide range of operating temperatures during prelaunch and ascent. Attention is given to the configuration of the Space Shuttle system, the configuration of the external tank, the initial ET TPS concept, TPS materials and processes concepts, design rationale, TPS materials structural considerations, material and processes development, development tests, material/process verification, and flight results.

Ronquillo, L.↗

Simulation of Deployable Composite Structures Based On Mechanics of Structure Genome

In this paper, a simulation method for analyzing deployable composite structures is presented. With a proper material model, effective plate/shell properties of the composites is obtained based on Mechanics of Structure Genome (MSG), and then implemented into a user subroutine UGENS for global structure simulation in ABAQUS. Column bending test (CBT) and composite boom and hub structure are studied for demonstration. A viscoelastic material model with direct integration implementation is adopted in this paper. CBT simulation shows good agreement with experiments during relaxation, while errors are observed when comparing residual deformation. This simulation can be potentially used as a calibration tool for material properties. After CBT simulation, a demonstrative model with a lenticular boom and the hub is created in ABAQUS. Complete process of flattening, coiling, stowage, deploying and recovery is simulated with the viscoelastic material model. Residual deformation of the boom is analyzed.

Multi-scale modeling↗

Machine-Learning-Driven Discovery of Water Splitting BaFe 2 O 4 and Human-in-the-Loop Improvement via Al-Substitution for Increased Thermal Stability

Thermochemical hydrogen (TCH) production offers a promising method for converting thermal energy into hydrogen fuel through heat-driven redox cycles of metal oxides. Here, in this work a defect graph neural network (dGNN) was used to predict oxygen vacancy formation energies ΔH V O combined with Materials Project predictions of oxygen chemical potential stability to screen candidate oxides via high-throughput database analysis. BaFe 2 O 4 was identified as a promising material for experimental validation based on its predicted ΔH V O , oxygen chemical potential stability range, and potential for tunable substitutions to improve thermal properties. Experimental validation using thermogravimetric analysis (TGA), stagnation flow reactor (SFR), X-ray diffraction (XRD), and electron microscopy confirmed positive water-splitting behavior but also revealed limitations in thermal stability under aggressive reduction conditions. To address this, a human-in-the-loop modification strategy was employed introducing Al substitution in BaFe 2–x Al x O 4 ; this modification improves thermal stability, alters the crystal structure and enhances overall performance. These results demonstrate a combined computational and experimental workflow in which machine learning accelerates identification of promising candidates, while targeted experimental design enables optimization of functional performance. This approach advances the development of robust, cost-effective TCH materials and highlights the importance of integrating data-driven discovery with human-guided materials design in paving the way for scalable hydrogen production technologies.

organic↗

The M-Integral for Computing Stress Intensity Factors in Generally Anisotropic Materials

The objective of this project is to develop and demonstrate a capability for computing stress intensity factors in generally anisotropic materials. These objectives have been met. The primary deliverable of this project is this report and the information it contains. In addition, we have delivered the source code for a subroutine that will compute stress intensity factors for anisotropic materials encoded in both the C and Python programming languages and made available a version of the FRANC3D program that incorporates this subroutine. Single crystal super alloys are commonly used for components in the hot sections of contemporary jet and rocket engines. Because these components have a uniform atomic lattice orientation throughout, they exhibit anisotropic material behavior. This means that stress intensity solutions developed for isotropic materials are not appropriate for the analysis of crack growth in these materials. Until now, a general numerical technique did not exist for computing stress intensity factors of cracks in anisotropic materials and cubic materials in particular. Such a capability was developed during the project and is described and demonstrated herein.

Warzynek, P. A.↗

Marshall Space Flight Center Materials and Processes Laboratory

Marshall?s Materials and Processes Laboratory has been a core capability for NASA for over fifty years. MSFC has a proven heritage and recognized expertise in materials and manufacturing that are essential to enable and sustain space exploration. Marshall provides a "systems-wise" capability for applied research, flight hardware development, and sustaining engineering. Our history of leadership and achievements in materials, manufacturing, and flight experiments includes Apollo, Skylab, Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, Chandra, and the International Space Station. MSFC?s National Center for Advanced Manufacturing, NCAM, facilitates major M&P advanced manufacturing partnership activities with academia, industry and other local, state and federal government agencies. The Materials and Processes Laborato ry has principal competencies in metals, composites, ceramics, additive manufacturing, materials and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide products ranging from materials research in space to fully integrated solutions for large complex systems challenges. Marshall?s materials research, development and manufacturing capabilities assure that NASA and National missions have access to cutting-edge, cost-effective engineering design and production options that are frugal in using design margins and are verified as safe and reliable. These are all critical factors in both future mission success and affordability.

Tramel, Terri L.↗

Integrated Approach to Post-Irradiation Examination of Nuclear Materials at Idaho National Laboratory

Idaho national Laboratory (INL) is the U.S. lead national laboratory for the Department of Energy’s Office of Nuclear Energy (DOE-NE), providing much of the nuclear research, development and demonstration capability needed to move nuclear innovation forward to deployment. INL’s Materials and Fuels Complex hosts a unique combination of personnel, facilities and infrastructure and offers the ability to perform post-irradiation examinations (PIE) of nuclear materials spanning multiple length scales. The ability to combine engineering-scale analysis and sub-microscopic characterization provides valuable insights into fuel and structural material behavior and degradation mechanisms. The holistic approach is used to accelerate these materials demonstration and deployment. Selected studies will be presented, highlighting the impact of these techniques on improving fuel reliability, safety, and efficiency, thereby advancing the development of sustainable and advanced nuclear energy technologies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Graphite/Ultra-High Modulus Polyethylene Hybrid Fiber Composites with Epoxy and Polyethylene Matrices for Cosmic Radiation Shielding

One of the most significant technical challenges in long-duration space missions is that of protecting the crew from harmful radiation. Protection against such radiation on a manned Mars mission will be of vital importance both during transit and while on the surface of the planet. The development of multifunctional materials that serve as integral structural members of the space vehicle and provide the necessary radiation shielding for the crew would be both mission enabling and cost effective. Additionally, combining shielding and structure could reduce total vehicle mass. Hybrid laminated composite materials having both ultramodulus polyethylene (PE) and graphite fibers in epoxy and PE matrices could meet such mission requirements. PE fibers have excellent physical properties, including the highest specific strength of any known fiber. Moreover, the high hydrogen (H) content of polyethylene makes the material an excellent shielding material for cosmic radiation. When such materials are incorporated into an epoxy or PE matrix a very effective shielding material is expected. Boron (B) may be added to the matrix resin or used as a coating to further increase the shielding effectiveness due to B s ability to slow thermal neutrons. These materials may also serve as micrometeorites shields due to PE s high impact energy absorption properties. It should be noted that such materials can be fabricated by existing equipment and methods. It is the objective of this work therefore to: (a) perform preliminary analysis of the radiation transport within these materials; (b) fabricate panels for mechanical property testing before and after radiation exposure. Preliminary determination on the effectiveness of the combinations of material components on both shielding and structural efficiency will be made.

Source record↗

Determining a Prony Series for a Viscoelastic Material From Time Varying Strain Data

In this study a method of determining the coefficients in a Prony series representation of a viscoelastic modulus from rate dependent data is presented. Load versus time test data for a sequence of different rate loading segments is least-squares fitted to a Prony series hereditary integral model of the material tested. A nonlinear least squares regression algorithm is employed. The measured data includes ramp loading, relaxation, and unloading stress-strain data. The resulting Prony series which captures strain rate loading and unloading effects, produces an excellent fit to the complex loading sequence.

Tzikang, Chen↗

A three-dimensional equivalent domain integral method for cracked solids

Three-dimensional FEM analysis is presently undertaken via the general formulation of the equivalent-domain integral method for mixed-mode fracture problems in general anisotropic and nonlinear materials. In mixed-mode integrals, the total J-integral is split into three separate modes of fracture; direct and decomposition methods are effective in this separation of the modes, as presently demonstrated by their application to several pure and mixed-mode fracture problems. The results are found to agree well with those reported in the literature, and suggest the usefulness of the method as a FEM-program postprocessing subroutines.

Shivakumar, K. N.↗

Melt Pool and Heat Treatment Optimization for the Fabrication of High-Strength and High-Toughness Additively Manufactured 4340 Steel

Additively manufactured (AM) components offer superior design flexibility compared to their conventionally manufactured counterparts, and optimizing processing parameters is key to achieving high-quality depositions with desirable and predictable mechanical properties. This study was focused on 4340 steel fabricated using laser powder bed fusion (LPBF), and 42 laser power and scan speed combinations have been systematically investigated to determine an optimized melt pool geometry that would ensure fully-dense parts. The AM material was compared with a wrought 4340 equivalent and studied in two customized heat treated conditions, optimized for strength and toughness, respectively. The microstructures of the as-fabricated and heat treated AM and wrought materials were characterized to assess differences introduced by the layer-by-layer fabrication process and subsequent heat treatment. Tensile properties of both materials were also evaluated and demonstrate that the AM materials offer equal or superior properties compared to the wrought equivalents. Differences in fracture surface morphologies indicate the distinct failure mechanisms associated with the materials’ characteristic microstructures, and the role of inclusions in the failures was studied to elucidate these differences. Complementary to the experimental investigations, the dataset was leveraged to make recommendations for future design of experiments to optimize AM build parameters in other material systems. A statistical Monte Carlo analysis was used to predict the interpolation error produced using reduced datasets and to enable informed processing parameters selection. These findings are discussed to make recommendations for the use of AM materials for high-integrity structural applications.

36 MATERIALS SCIENCE↗

Sampling lattices in semi-grand canonical ensemble with autoregressive machine learning

Calculating thermodynamic potentials and observables efficiently and accurately is key for the application of statistical mechanics simulations to materials science. However, naive Monte Carlo approaches, on which such calculations are often dependent, struggle to scale to complex materials in many state-of-the-art disciplines such as the design of high entropy alloys or multi-component catalysts. To address this issue, we adapt sampling tools built upon machine learning-based generative modeling to the materials space by transforming them into the semi-grand canonical ensemble. Furthermore, we show that the resulting models are transferable across wide ranges of thermodynamic conditions and can be implemented with any internal energy model U, allowing integration into many existing materials workflows. We demonstrate the applicability of this approach to the simulation of benchmark systems (AgPd, CuAu) that exhibit diverse thermodynamic behavior in their phase diagrams. Finally, we discuss remaining challenges in model development and promising research directions for future improvements.

36 MATERIALS SCIENCE↗

Mechanical Erosion Modeling of TPS Materials

The goal of this work is to predict the mechanical response of TPS materials, and specifically, to determine if there is additional surface recession in the heat shield’s surface as a result of mechanical erosion due to the mechanical and thermal loads experienced during atmospheric entry. To accomplish this, a solid mechanics module was integrated within the PATO material response code, enabling it to model the potential mechanical erosion in three steps: first, having the effective mechanical properties as function of temperature, the implemented stress analysis solver computes the stress and the displacement fields for the TPS material using the wall shear stress tensor, computed with the DPLR hypersonic CFD code, as boundary conditions; then, regions on the surface where the stress meets the failure criteria are identified; finally, the failed material is removed and the mesh is redistributed accordingly. The outcome is a model capable of predicting the total recession in the TPS material due to surface chemistry and mechanical erosion.

Stress Analysis↗

Mitigation for Removal of Building 01-202681 in the Main Storage Yard of the Area 1 Subdock, Nevada National Security Site, Nye County, Nevada

The Main Storage Yard was originally recorded as SHPO Resource No. S2772 in 2020 during an architectural survey of the Area 1 Subdock (Collins et al. 2022). It was recommended individually eligible for listing in the NRHP under Criteria A and C and as contributing to the significance of the potential Area 1 Subdock Historic District. The SHPO concurred with these determinations in a letter dated April 29, 2022 (Reed). The Main Storage Yard retains all seven aspects of integrity. The location, design, materials, workmanship, feeling, and association have not changed since the original construction. Since the purpose of the yard is to maintain storage equipment that is actively being used, the design and feeling will change each time equipment is moved. Such actions reinforce the integrity of design and feeling. Buildings 01-101 and 01-102 were removed (Collins and Menocal 2020), but the other buildings and storage yard remain. Therefore, the setting has been changed, but not to the degree that the Main Storage Yard no longer conveys its significance (see Figures 4 and 5 for comparison). The Main Storage Yard was designed to facilitate the relocation of the Area 3 Subdock to Area 1 in 1985. The design for the overall Subdock provided a centralized cluster of buildings surrounded by two large storage yards. While the North Storage Yard largely serves as overflow storage, the Main Storage Yard holds the majority of drill rigs and drilling equipment needed to support big hole drilling. The Main Storage Yard and its contents were essential elements of the nuclear testing drilling program on the NNSS thus making it eligible for the NRHP under Criterion A for its contribution to broad patterns of history by storing specially designed equipment for underground nuclear testing at the NNSS. It is also eligible under Criterion C as it is an engineered landscape that now serves as an open-air repository of drilling technology and nuclear testing. In addition to its individual significance, the Main Storage Yard also contributes to the significance of the Area 1 Subdock Historic District as it showcases a variety of big-hole drilling equipment, support facilities, and warehouses that were specially designed for nuclear testing at the NNSS. Despite the demolition of two contributing elements to date, the district still contains numerous examples of other facilities with the purpose of supporting big-hole drilling; therefore, the district still remains eligible under Criteria A and C.

54 ENVIRONMENTAL SCIENCES↗

Solar Pumped High Power Solid State Laser for Space Applications

Highly coherent laser light provides a nearly optimal means of transmitting power in space. The simplest most direct means of converting sunlight to coherent laser light is a solar pumped laser oscillator. A key need for broadly useful space solar power is a robust solid state laser oscillator capable of operating efficiently in near Earth space at output powers in the multi hundred kilowatt range. The principal challenges in realizing such solar pumped laser oscillators are: (1) the need to remove heat from the solid state laser material without introducing unacceptable thermal shock, thermal lensing, or thermal stress induced birefringence to a degree that improves on current removal rates by several orders of magnitude and (2) to introduce sunlight at an effective concentration (kW/sq cm of laser cross sectional area) that is several orders of magnitude higher than currently available while tolerating a pointing error of the spacecraft of several degrees. We discuss strategies for addressing these challenges. The need to remove the high densities of heat, e.g., 30 kW/cu cm, while keeping the thermal shock, thermal lensing and thermal stress induced birefringence loss sufficiently low is addressed in terms of a novel use of diamond integrated with the laser material, such as Ti:sapphire in a manner such that the waste heat is removed from the laser medium in an axial direction and in the diamond in a radial direction. We discuss means for concentrating sunlight to an effective areal density of the order of 30 kW/sq cm. The method integrates conventional imaging optics, non-imaging optics and nonlinear optics. In effect we use a method that combines some of the methods of optical pumping solid state materials and optical fiber, but also address laser media having areas sufficiently large, e.g., 1 cm diameter to handle the multi-hundred kilowatt level powers needed for space solar power.

Fork, Richard L.↗

A multiaxial theory of viscoplasticity for isotropic materials

Many viscoplastic constitutive models for high temperature structural alloys are based exclusively on uniaxial test data. Generalization to multiaxial states of stress is made by assuming the stress dependence to be on the second principal invariant (J sub 2) of the deviatoric stress, frequently called the effective stress. If such a J sub 2 theory, based on uniaxial testing, is called upon to predict behavior under conditions other than uniaxial, e.g., pure shear, and it does so poorly, nothing is left to adjust in the theory. For a fully isotropic material whose inelastic deformation behavior is relatively independent of hydrostatic stress, the most general stress dependence is on the two (non-zero) principal invariants of the deviatoric stress, J sub 2 and J sub 3. These invariants constitute what is known as an integrity basis for the material. A time dependent constitutive theory with stress dependence on J sub 2 and J sub 3 is presented, that reduces to a known J sub 2 theory as a special case.

Robinson, D. N.↗