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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 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Composite Hard Upper Torso (CHUT) for xEMU Space Suit

The xEMU is the Exploration Mobility Unity or space suit designed for microgravity (cislunar and low earth orbit (LEO)) and lunar surface operations. This suit design allows crewmembers to perform extravehicular exploration, science, construction, maintenance, and contingency operations while unattached to a vehicle for life support in pressure and thermal environments that exceed human capability. The xEMU provides life support, environmental protection, and communications capabilities to the EVA crewmember while allowing sufficient mobility and visibility to perform dexterous EVA tasks. The effort documented in this paper, addressed the design, analysis, manufacturing, full-scale test article testing and validation for a Composite Hard Upper Torso(CHUT)unit. Design and analysis of the CHUT was based on measured B-basis properties of the selected S-glass/epoxy composite, and established final geometry, composite layup and interface details that met requirements. A complete manufacturing and assembly protocol was established for the CHUT starting from composite layup in the tool, to final assembly of all interface metal hardware prior to delivery to NASA for suit integration. Full-scale CHUT test articles underwent static and fatigue pressure testing (2 lifetimes), impact testing at critical stress locations for tool drop/microgravity scenarios, followed by post-impact fatigue testing. Effect of manufacturing defects was evaluated by manufacturing a full-scale CHUT with 0.375”/0.5” defects at critical stress locations, followed by static and life-cycle fatigue testing. In all cases, the CHUT design met or exceeded mass, structural, interface and functional requirements. Two (2) complete CHUT articles were delivered to NASA for full-scale suit integration and testing.

spacesuit↗
DOE OSTI2016

Spent nuclear fuel dynamic performance under normal conditions of transport

The objective of this project is to evaluate the spent nuclear fuel (SNF) vibration integrity under normal condition of transport. The SNF fatigue strength data has been collected from various pressurized water reactors. The CIRFT (Cyclic Integrated Reversible-Bending Fatigue Tester) has been used to simulate transportation environments. CIRFT is an enabling hot-cell testing technology developed at Oak Ridge National Laboratory (ORNL). The CIRFT consists mainly of a U-frame testing setup and a real-time curvature measurement method. The three-component U-frame setup of the CIRFT has two rigid arms and linkages to a universal testing machine. The curvature of rod bending is obtained through a three-point deflection measurement method. Three linear variable differential transformers (LVDTs) are used and clamped to the side connecting plates of the U-frame to capture the deformation of the rod. CIRFT results have provided insight into the fuel/clad system response to transportation related loads. Because of the non-homogeneous composite structure of the SNF system, finite element analyses (FEA) are needed to translate the global moment-curvature measurement into local stress-strain profiles. The detailed mechanisms of the pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained directly from a CIRFT system measurement. Therefore, detailed FEA is used to understand the global test response. The major findings of CIRFT test on the high burn-up SNF are as follows: -) SNF system interface bonding plays an important role in SNF vibration performance; -) Fuel structure contributes to the SNF system stiffness; -) There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellets and clad interaction, and -) SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous.

42 ENGINEERING↗
DOE OSTI2015

High burn-up spent nuclear fuel vibration integrity study - 15134

The Oak Ridge National Laboratory (ORNL) has developed the cyclic integrated reversible-bending fatigue tester (CIRFT) approach to successfully demonstrate the controllable fatigue fracture of high burnup (HBU) spent nuclear fuel (SNF) in a normal vibration mode. CIRFT enables examination of the underlying mechanisms of SNF system dynamic performance. Due to the inhomogeneous composite structure of the SNF system, the detailed mechanisms of pellet-pellet and pellet-clad interactions and the stress concentration effects at the pellet-pellet interface cannot be readily obtained from a CIRFT system measurement. Therefore, finite element analyses (FEAs) are being used to complement the experimental work by estimating values of local stresses and strains from the measured global moment-curvature. These results and their implications will be used for further investigation. Major findings of CIRFT on the HBU SNF are as follows: - The degree of bonding between pellets, as well as the bonding between pellets and clad in the SNF system plays an important role in the vibration performance of SNF. - Fuel structure contributes to SNF system stiffness. - There are significant variations in stress and curvature of SNF systems during vibration cycles resulting from segment pellet and clad interactions. - SNF failure initiates at the pellet-pellet interface region and appears to be spontaneous. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1984

NASA welding assessment program

A long duration test has been conducted for comparing various methods of attaching electrical interconnects to solar cells for near Earth orbit spacecraft. Representative solar array modules have been thermally cycled for 36,000 cycles between -80 and +80 C on this JPL and NASA Lewis Research Center sponsored work. This test simulates the environmental stress of more than 6 years on a near Earth spacecraft as it cycles in and out of the Earth's shadow. Evaluations of the integrity of these modules were made by visual and by electrical examinations before starting the cycling and then at periodic intervals during the cycling tests. Modules included examples of parallel gap and of ultrasonic welding, as well as soldering. The materials and fabrication processes are state of the art, suitable for forming large solar arrays of spacecraft quality. The modules survived his extensive cycling without detectable degradation in their ability to generate power under sunlight illumination.

Stofel, E. J.↗
NASA NTRS1985

Cast iron-base alloy for cylinder/regenerator housing

NASACC-1 is a castable iron-base alloy designed to replace the costly and strategic cobalt-base X-40 alloy used in the automotive Stirling engine cylinder/generator housing. Over 40 alloy compositions were evaluated using investment cast test bars for stress-rupture testing. Also, hydrogen compatibility and oxygen corrosion resistance tests were used to determine the optimal alloy. NASACC-1 alloy was characterized using elevated and room temperature tensile, creep-rupture, low cycle fatigue, heat capacity, specific heat, and thermal expansion testing. Furthermore, phase analysis was performed on samples with several heat treated conditions. The properties are very encouraging. NASACC-1 alloy shows stress-rupture and low cycle fatigue properties equivalent to X-40. The oxidation resistance surpassed the program goal while maintaining acceptable resistance to hydrogen exposure. The welding, brazing, and casting characteristics are excellent. Finally, the cost of NASACC-1 is significantly lower than that of X-40.

Witter, Stewart L.↗
NASA NTRS2011

Thermal Cycling and Isothermal Deformation Response of Polycrystalline NiTi: Simulations vs. Experiment

A recent microstructure-based FEM model that couples crystal-based plasticity, the B2<-> MB190 phase transformation and anisotropic elasticity at the grain scale is calibrated to recent data for polycrystalline NiTi (49.9 at.% Ni). Inputs include anisotropic elastic properties, texture and differential scanning calorimetry data, as well as a subset of recent isothermal deformation and load-biased thermal cycling data. The model is assessed against additional experimental data. Several experimental trends are captured - in particular, the transformation strain during thermal cycling monotonically increases and reaches a peak with increasing bias stress. This is achieved, in part, by modifying the martensite hardening matrix proposed by Patoor et al. [Patoor E, Eberhardt A, Berveiller M. J Phys IV 1996;6:277]. Some experimental trends are underestimated - in particular, the ratcheting of macrostrain during thermal cycling. This may reflect a model limitation that transformation-plasticity coupling is captured on a coarse (grain) scale but not on a fine (martensitic plate) scale.

Manchiraju, Sivom↗
DOE OSTI2021

Experimental Investigation of Concrete Fatigue in Axial Compression

The use of concrete in fatigue critical structures, such as wind turbine towers, has necessitated the replacement of simplistic (and therefore insufficient) fatigue design recommendations with more accurate and advanced fatigue models that can consider a greater complexity of stress states and materials. As the first part of a multistage test series, an experimental investigation was conducted to determine the fatigue life of concrete subjected to axial compressive fatigue loading, focusing on the relatively high-cycle fatigue domain. Here, a wide range of values for maximum stress levels and stress ratios were considered. The experimental results were compared against existing predictive models, and the most applicable model was identified. Concrete strain and stiffness behavior during fatigue loading were also investigated and reported. Based on the observed behavior, a hypothesis for identifying the impending occurrence of fatigue failure, based on the monotonic stress-strain curve, is examined.

17 WIND ENERGY↗
NASA NTRS1974

An elastoplastic analysis of a uniaxially loaded sheet with an interference-fit bolt

The stresses and strains in a uniaxially loaded sheet with an unloaded interference-fit bolt were calculated by an elastoplastic finite-element analysis. The material properties represented a 7075-T6 aluminum alloy sheet and a steel bolt. The analysis considered the two ideal cases of no slip and no friction at the bolt-sheet interface for a single combination of bolt diameter, interference level, and cyclic loading. When the bolt was inserted, the sheet deformed plastically near the hole; the first tensile load cycle produced additional yielding, but subsequent cycles to the same level caused only elastic cyclic stresses. These stresses together with fatigue data for unnotched specimens were used to estimate crack initiation periods and initiation sites. The cases analyzed with interference-fit bolts were predicted to have crack initiation periods which were about 50 times that for a clearance-fit bolt. Crack initiation was predicted to occur on the transverse axis at a distance of about one radius from the hole.

Crews, J. H., Jr.↗
NASA NTRS1989

The low cycle fatigue deformation response of a single-crystal superalloy at 650 C

The cyclic stress-strain response and the associated deformation structure of the single crystal nickel-base superalloy PWA 1480 were investigated. Specimens of various crystallographic orientations were tested in low-cycle fatigue (LCF) at 650 C, resulting in a significant tension-compression anisotropy in initial yield strength associated with the shearing of gamma-prime precipitates by dislocation pairs, and a LCF cyclic hardening of the crystals associated with dislocation interactions occurring in the gamma phase. In specimens deforming by slip on a single slip system, dislocations of the primary slip system accumulated in the gamma matrix and formed seesile entanglements. In specimens deforming by slip on several slip systems, the dislocations of the different operative slip systems intersected in the gamma matrix and formed sessile arrangements.

Gabb, T. P.↗
DOE OSTI2015

System-Level Heat Transfer Analysis, Thermal- Mechanical Cyclic Stress Analysis, and Environmental Fatigue Modeling of a Two-Loop Pressurized Water Reactor. A Preliminary Study

This report provides an update on an assessment of environmentally assisted fatigue for light water reactor components under extended service conditions. This report is a deliverable in April 2015 under the work package for environmentally assisted fatigue under DOE's Light Water Reactor Sustainability program. In this report, updates are discussed related to a system level preliminary finite element model of a two-loop pressurized water reactor (PWR). Based on this model, system-level heat transfer analysis and subsequent thermal-mechanical stress analysis were performed for typical design-basis thermal-mechanical fatigue cycles. The in-air fatigue lives of components, such as the hot and cold legs, were estimated on the basis of stress analysis results, ASME in-air fatigue life estimation criteria, and fatigue design curves. Furthermore, environmental correction factors and associated PWR environment fatigue lives for the hot and cold legs were estimated by using estimated stress and strain histories and the approach described in NUREG-6909. The discussed models and results are very preliminary. Further advancement of the discussed model is required for more accurate life prediction of reactor components. This report only presents the work related to finite element modelling activities. However, in between multiple tensile and fatigue tests were conducted. The related experimental results will be presented in the year-end report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Fracture mechanics approach to TRISO fuel particle failure analysis

Weibull stress-based methods for failure probability assessment have been developed and analyzed to assess the integrity of tristructural isotropic (TRISO) fuel particles during fuel life cycles and accident operating conditions. While simple, these methods entail a number of drawbacks when stress concentrates near crack tips, including finite element mesh size dependency when the Weibull stress is averaged over the finite element domain. Fracture mechanics approaches involving the use of interaction integrals eliminate this lack of mesh convergence and produce consistent fracture predictions. In this work, we use an interaction integral approach to computing stress intensity factors for a crack in the inner pyrolytic carbon layer perpendicular to the silicon carbide layer, which is simplified representation of a failure mode in TRISO particles. Further, the interface between these two TRISO layers has been shown to become porous, which we simulate by considering a transition of mechanical properties over such porous length, i.e. the layers are modeled as a functionally graded material. Aspects such as porosity and thermal and irradiation eigenstrains are considered in computing the stress intensity factor from a fracture mechanics approach and compared with the known Weibull stress failure approach. The methodology introduced in this paper enables a more general fracture probability assessment in TRISO particles and eliminates the need to identify best suited parameters when using local or averaged stress-based failure criterion. Finally, the numerical sensitivity studies show how parameters such as the porous transition zone length, the material stiffness, and creep affect the probability of TRISO fuel particle failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Effects of size and concentration on diffusion-induced stress in lithium-ion batteries

Capacity fade of lithium-ion batteries induced by chemo-mechanical degradation during charge-discharge cycles is the bottleneck in design of high-performance batteries, especially high-capacity electrode materials. Stress generated due to diffusion-mechanical coupling in lithium-ion intercalation and deintercalation is accompanied by swelling, shrinking, and even micro-cracking. In this paper, we propose a theoretical model for a cylindrical nanowire electrode by combining the bond-order-length-strength and diffusion theories. It is shown that size and concentration have a significant influence on the stress fields in radial, hoop, and axial directions. This can explain why a smaller electrode with a huge volume change survives in the lithiation/delithiation process.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Pt–Co truncated octahedral nanocrystals: a class of highly active and durable catalysts toward oxygen reduction

We report a facile and scalable synthesis of Pt–Co truncated octahedral nanocrystals (TONs) by employing Pt(acac) 2 and Co(acac) 2 as precursors, together with CO molecules and Mn atoms derived from the decomposition of Mn 2 (CO) 10 as a reductant and a {111} facet-directing agent, respectively. Both the composition and yield of the Pt–Co TONs could be varied through the introduction of CHCl 3 . When tested at 80 °C using membrane electrode assembly (MEA), the 4 nm Pt 2.6 Co TONs gave a mass activity of 294 A g Pt –1 at beginning-of-life (BOL) and it increased to 384 A g Pt –1 during recovery cycles. The mass activity at BOL only dropped by 24% after 30 000 voltage cycles at end-of-life (EOL) in a metal dissolution accelerated stress test. The Pt 2.6 Co/C catalyst outperformed the commercial TKK Pt 3 Co/C (230 A g Pt –1 at BOL and 40% loss after 30 000 cycles at EOL) in terms of both activity and durability. Our systematic analysis suggested that the enhancement in activity can be attributed to the combination of small, uniform size and well-defined {111} facets. This new class of catalysts holds promise for applications in proton-exchange membrane fuel cells.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Neutron residual stress measurement and numerical modeling in a curved thin-walled structure by laser powder bed fusion additive manufacturing

Severe residual stresses in metal parts made by laser powder bed fusion additive manufacturing processes (LPBFAM) can cause both distortion and cracking during the fabrication processes. Limited data is currently available for both iterating through process conditions and design, and in particular, for validating numerical models to accelerate process certification. In this work, residual stresses of a curved thin-walled structure, made of Ni-based superalloy Inconel 625™ and fabricated by LPBFAM, were resolved by neutron diffraction without measuring the stress-free lattices along both the build and the transverse directions. The stresses of the entire part during fabrication and after cooling down were predicted by a simplified layer-by-layer finite element based numerical model. The simulated and measured stresses were found in good quantitative agreement. The validated simplified simulation methodology will allow to assess residual stresses in more complex structures and to significantly reduce manufacturing cycle time.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigating ceramic breeder pebble beds thermomechanics evolution using novel pressure mapping technology

Ceramic breeder pebble beds undergo complex thermomechanical interactions during blanket operation due to stress build-up and relaxation under the effects of confined thermal expansion, thermal cycling, and creep. Understanding the evolution of such processes can aid in guiding blanket design/assembly, breeder materials developments, predicting performance and possible failure modes. This study introduces experimental techniques that enable us to create an environment in which the pebble bed stresses are organically generated as a result of relevant temperature gradients and magnitudes that allows us to observe the combined thermomechanical interaction effects. A novel non-intrusive in-situ tactile pressure sensing technology is used to generate real-time contact pressure maps revealing the spatial and temporal stress evolution with emphasis on understanding the roles that each of the thermo-mechanical forces play in dictating the pebble bed’s equilibrium conditions. Two types of bed-wall contact pressure drop were recorded: (1) within the subsequent cycles due to pebbles irreversible rearrangements, and (2) within the cycle itself as a result of creep/stress-relaxation. Consequently, by the fourth cycle, the contact pressure drops to negligible values and remains stable. This stability is attributed to two modes of self-regulation: (1) stress self-regulation as a result of pressure rise and fall due to thermal expansion and creep/thermal cycling, respectively, and (2) temperature self-regulation due to the locally enhanced thermal conductivity in the core region of the bed accompanied by deteriorated interface conductance. These two mechanisms are desirable as they lower the probability of the events of pebbles crushing and thermal runaways under high temperatures/stresses and poor heat extraction.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Seasonal variability of forest sensitivity to heat and drought stresses: A synthesis based on carbon fluxes from North American forest ecosystems

Climate extremes such as heat waves and droughts are projected to occur more frequently with increasing temperature and an intensified hydrological cycle. It is important to understand and quantify how forest carbon fluxes respond to heat and drought stress. In this study, we developed a series of daily indices of sensitivity to heat and drought stress as indicated by air temperature (T a ) and evaporative fraction (EF). Using normalized daily carbon fluxes from the FLUXNET Network for 34 forest sites in North America, the seasonal pattern of sensitivities of net ecosystem productivity (NEP), gross ecosystem productivity (GEP) and ecosystem respiration (RE) in response to T a and EF anomalies were compared for different forest types. The results showed that warm temperatures in spring had a positive effect on NEP in conifer forests but a negative impact in deciduous forests. GEP in conifer forests increased with higher temperature anomalies in spring but decreased in summer. The drought-induced decrease in NEP, which mostly occurred in the deciduous forests, was mostly driven by the reduction in GEP. In conifer forests, drought had a similar dampening effect on both GEP and RE, therefore leading to a neutral NEP response. The NEP sensitivity to T a anomalies increased with increasing mean annual temperature. Drier sites were less sensitive to drought stress in summer. Natural forests with older stand age tended to be more resilient to the climate stresses compared to managed younger forests. The results of the Classification and Regression Tree analysis showed that seasons and ecosystem productivity were the most powerful variables in explaining the variation of forest sensitivity to heat and drought stress. Our results implied that the magnitude and direction of carbon flux changes in response to climate extremes are highly dependent on the seasonal dynamics of forests and the timing of the climate extremes.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS2017

Compounding Impacts of Human-Induced Water Stress and Climate Change on Water Availability

The terrestrial phase of the water cycle can be seriously impacted by water management and human water use behavior (e.g., reservoir operation, and irrigation withdrawals). Here we outline a method for assessing water availability in a changing climate, while explicitly considering anthropogenic water demand scenarios and water supply infrastructure designed to cope with climatic extremes. The framework brings a top-down and bottom-up approach to provide localized water assessment based on local water supply infrastructure and projected water demands. When our framework is applied to southeastern Australia we find that, for some combinations of climatic change and water demand, the region could experience water stress similar or worse than the epic Millennium Drought. We show considering only the influence of future climate on water supply, and neglecting future changes in water demand and water storage augmentation might lead to opposing perspectives on future water availability. While human water use can significantly exacerbate climate change impacts on water availability, if managed well, it allows societies to react and adapt to a changing climate. The methodology we present offers a unique avenue for linking climatic and hydrologic processes to water resource supply and demand management and other human interactions.

Climate-change policyHydrology↗