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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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DOE OSTI2021

FY21 Status Report on Creep Rupture Testing at ANL to Support the Development of Alloy 709 Code Case

This report provides an update on the status of the creep rupture testing on the first commercial heat of Alloy 709 in support of the Alloy 709 Code Case development. Creep tests were performed in air on the lever-arm load frames in the Mechanical and Environmental Testing Laboratory at Argonne National Laboratory (ANL). In FY21, the focus was on the age-hardened ESR-1150°C material. Twenty two tests were initiated, among which ten were completed. This report presents the data from the completed tests. Metallographic characterization of the fractured specimens were performed and the results are included. The creep data enabled the preliminary analysis of the creep behavior of this material. The characterization showed the effect of test temperature and stress on the deformation microstructure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Non-Nuclear Test Facility Development to Support Verification and Validation Needs

This study focuses on developing a non-nuclear test facility to help meet the verification and validation (V&V) requirements of a water-cooled small modular reactor (SMR) system. The scaling analysis necessary for reactor system experimentation and assessment model V&V considers various reactor system accident scenarios such as main steam line break (MSLB), steam generator tube rupture (SGTR), and containment condensation and heat transfer. The goal is to identify key physics based phenomena of interest (POI), specific figures of merit (FOMs), and the state of knowledge (SOK) by employing phenomena identification and ranking table (PIRT) studies. Important physics phenomena such as heat transfer, fluid dynamics, structural integrity, and material selection must be addressed when scaling a thermal-hydraulics system. Alongside these considerations, modifications to the facility may be needed to align the scaled system with the available footprint (height and space) of the facility. These modifications may include infrastructure upgrades, changes to the piping layout, implementation of safety measures, and installation of new instrumentation and control systems. The test facility aims to provide a scaled-down version of prototypic facilities for comprehensive V&V activities by overcoming these challenges and making the necessary modifications. This approach minimizes scaling distortion, simulates prototypic plant conditions, and accurately models accident event progressions. Thus, the facility will be capable of adequately modeling a scaled SMR system to support the design, development and licensing needs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

IMPLEMENTATION OF TURBULENCE MODELING FOR THE COUPLED GRIFFIN-PRONGHORN SIMULATION OF THE MOLTEN SALT FAST REACTOR FOR THE VIRTUAL TEST BED

In support of the Virtual Test Bed (VTB) repository, the Molten Salt Fast Reactor (MSFR) concept is modeled using MOOSE-based tools, notably Griffin and Pronghorn, employing newly implemented initial turbulence models and standard wall functions. The models are adapted to Pronghorn’s spirit of a multidimensional coarse-mesh intermediate fidelity code. Multiphysics simulations of a 2D axisymmetric model of an MSFR are carried out to study the coupling between the different physics.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Validation and Recalibration of the Solubility Models in Support of the Heater Test in Salt Formations

The US Department of Energy Office of Nuclear Energy is conducting a brine availability heater test to characterize the thermal, mechanical, hydrological and chemical response of salt at elevated temperatures. In the heater test, brines will be collected and analyzed for chemical compositions. In order to support the geochemical modeling of chemical evolutions of the brines during the heater test, we are recalibrating and validating the solubility models for the mineral constituents in salt formations up to 100°C, based on the solubility data in multiple component systems as well as simple systems from literature. In this work, we systematically compare the model-predicted values based on the various solubility models related to the constituents of salt formations, with the experimental data. As halite is the dominant constituent in salt formations, we first test the halite solubility model in the Na-Mg-Cl dominated brines. We find the existing halite solubility model systematically over-predict the solubility of halite. We recalibrate the halite model, which can reproduce halite solubilities in Na-Mg-Cl dominated brines well. As gypsum/anhydrite in salt formations controls the sulfate concentrations in associated brines, we test the gypsum solubility model in NaCl solutions up to 5.87 mol•kg –1 from 25 ° C to 50 ° C. The testing shows that the current gypsum solubility model reproduces the experimental data well when NaCl concentrations are less than 1 mol•kg –1 . However, at NaCl concentrations higher than 1, the model systematically overpredicts the solubility of gypsum. In the Na + —Cl – —SO 4 2– —CO 3 2– system, the validation tests up to 100 ° C demonstrate that the model excellently reproduces the experimental data for the solution compositions equilibrated with one single phase such as halite (NaCl) or thenardite (Na 2 SO 4 ), with deviations equal to, or less than, 1.5 %. The model is much less ideal in reproducing the compositions in equilibrium with the assemblages of halite + thenardite, and of halite + thermonatrite (Na 2 CO 3 •H 2 O), with deviations up to 31 %. The high deviations from the experimental data for the multiple assemblages in this system at elevated temperatures may be attributed to the facts that the database has the Pitzer interaction parameters for Cl – —CO 3 2– and SO 4 2– —CO 3 2– only at 25 ° C. Finally, in the Na + —Ca 2+ —SO 4 2– —HCO 3 – system, the validation tests also demonstrate that the model reproduces the equilibrium compositions for one single phase such as gypsum better than the assemblages of more than one phase.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Nonnuclear Experimental Capabilities to Support Design, Development, and Demonstration of Microreactors

This work provides a summary of selected experimental capabilities being developed to support nonnuclear testing and demonstration of technology in support of microreactors under the U.S. Department of Energy’s (DOE’s) Microreactor Program. Major capabilities include the Single Primary Heat Extraction and Removal Emulator (SPHERE) and the Microreactor Agile Non-nuclear Experimental Test Bed (MAGNET). The SPHERE facility allows for controlled testing of the steady-state and transient heat rejection capabilities of a single heat pipe using electrical heaters that simulate nuclear heating. The facility is capable of monitoring axial temperature profiles along the heat pipe and surrounding test articles during startup, steady-state operation, and transients. Instrumentation includes noncontact infrared thermal imaging, surface thermocouples, spatially distributed fiber optic temperature and strain sensors, electrical power meters, and a water-cooled, gas-gap calorimeter for quantifying heat rejection from the heat pipe. The facility can be operated under both vacuum and inert-gas conditions. The MAGNET facility is a large-scale, 250-kW electrically heated microreactor test bed to enable nonnuclear experimental evaluation of a variety of microreactor concepts. It can be supplied to electrically heat a scaled section of a microreactor and further test the capabilities of heat rejection systems. The initial MAGNET experiments will support technology maturation and reduce uncertainty and risk associated with the design, operation, and deployment of monolithic heat pipe–based reactors. However, this test bed can broadly be applied to multiple microreactor concepts to evaluate a wide range of thermal-hydraulic and structural phenomena such as interface coupling with power conversion units and other collocated systems. MAGNET can evaluate integral thermomechanical effects during electrical heating of an array of heat pipes in a larger test article. Examples of initial testing will include thermal stresses in the monolith and the impact of debonding of a heat pipe from the core block and how that failure could impact surrounding heat pipes, i.e., understanding the potential for cascading failure. This work also discusses some modeling capabilities that can support experiment design, analysis, and interpretation, including the heat pipe code Sockeye and a comparison of thermal-structural simulations performed using ABAQUS and STAR-CCM+.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Advanced Test Reactor (ATR) Capabilities in Support of Advanced Reactor Development [Slides]

A primary mission of the Advanced Test Reactor (ATR) is to support the next generation of nuclear reactors. This is an overview of ATR irradiation capabilities in support of advanced reactor development. Topics include an overview of the ATR facility and reactor, experiment design overview, thermal and fast spectrum testing, as well as advanced material testing.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

Coupled Multiphysics Primary Loop Simulations of the Mk1-FHR in the Virtual Test Bed

To support advanced reactor demonstrations, the Virtual Test Bed (VTB) [1] repository hosts a wide range of challenge problems for showcasing modeling and simulation capabil- ities in support of advanced reactor demonstrations. This document presents a coupled multiphysics model of the Mark 1 pebble-bed fluoride-salt-cooled high-temperature reactor (PB-FHR). The analysis leverages NEAMS tools (Griffin [2], SAM [3], Pronghorn [4], and the MOOSE [5] heat con- duction module) for core neutronics, thermal hydraulics of the core and primary loop, and multiscale fuel performance simulations. The analysis was entirely created by coupling standalone simulations of the reactor that were previously available on the VTB. All input files and documentation de- veloped for this example are available on the VTB website: mooseframework.inl.gov/ virtual_test_bed/ . This model was featured in the National Reactor Innovation Cen- ter Tech Talk presented in December 2021.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Report on FY 2020 testing of Alloy 709 in support of EPP analysis

Research activities in support of the development of a 500,000 hr, 760ºC ASME Code Case (CC) for Alloy 709 are ongoing at Oak Ridge National Laboratory (ORNL), Argonne National Laboratory, and Idaho National Laboratory. Integration of the simplified Elastic-Perfectly Plastic (EPP) methods for the design of Alloy 709 reactor components is a requirement for the Alloy 709 CC. This report documents the research plans and initiation of testing in support of integrating EPP analysis methods for Alloy 709 at ORNL in FY 2020. Tests are designed and initiated to evaluate the effect of cyclic loading on the creep properties of Alloy 709. The preliminary results show that cyclic loading has an insignificant effect on the minimum creep rate, although additional tests are recommended to confirm this conclusion. A preliminary testing plan for multi-axial creep rupture has been established and the specimens are machined. Execution of the testing plan will continue in FY 2021.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

An Architectural Survey of the U12G Tunnel Historic District, Nevada National Security Site, Nye County, Nevada

The U.S. Department of Energy (DOE), in conjunction with the National Nuclear Security Administration Nevada Field Office (NNSA/NFO), proposes to demolish six buildings and three storage areas located at the U12g Tunnel portal area in Area 12 of the Nevada National Security Site (NNSS). The buildings are 12-358 (Signal Vault); 12-201800 (Storage Quonset Hut); 12-202555 (Walker Shack); 12-868 (Pipe Assembly); 12-B100933 (Electrical Shop); 12-B100944 (Conference Room); and Storage Area 1; Storage Area 2; and Storage Area 3. The buildings and storage areas were selected for demolition as part of the DOE’s Real Property Efficiency Plan to reduce the footprint of unused and non-operational facilities on the NNSS. They are all vacant and have no proposed uses for current or upcoming NNSS missions. Demolition activities constitute an undertaking subject to review under Section 106 of the National Historic Preservation Act (NHPA) (54 United States Code [USC] § 306101) and its implementing regulations, 36 Code of Federal Regulations (CFR) Part 800. Identification efforts began with resources proposed for demolition in federal Fiscal Year (FY) 23. Four buildings were proposed to be demolished in FY23 (12-358, 12-868, 12-201800, and 12-202555). These buildings and the U12g Tunnel Historic District (SHPO No. D444) were recorded in Identification, Evaluation, and Finding of Adverse Effect for the Proposed Demolition of Five Buildings in Area 12, Nevada National Security Site, Nye County, Nevada (Menocal et al. 2023). Identification efforts indicated three buildings (12-358, 12-201800, and 12-868) supported nuclear testing in the U12g Tunnel. The fourth building post-dated the use of U12g Tunnel for nuclear testing activities. The report recommended that three of the four buildings (12-358, 12-201800, 12-868) and the U12g Tunnel Historic District may be eligible for the National Register of Historic Places (NRHP). The report also found that the undertaking would have an adverse effect on the three buildings and on the historic district. The Nevada State Historic Preservation Office (SHPO) concurred with the report’s findings (Reed 2023). The U12g Tunnel was determined eligible as a historic district under the Secretary of the Interior’s (SOI) Significance Criterion A, at the local level, in the context of the Cold War as an underground testing environment for the development of nuclear weapons and to assess the effects of a nuclear explosion on materials and equipment with a period of significance from 1959 to 1971. It was also determined eligible under Significance Criterion C for embodying the distinctive characters of a horizontal tunnel complex used for nuclear testing and as a significant and distinguishable entity. The three buildings were determined to be contributing elements of the district. The undertaking was expanded with the addition of two buildings and three storage areas proposed to be demolished and located within U12g Tunnel Historic District in FY24. These five resources (12-B100933, 12-B100944, and Storage Areas 1, 2, and 3) were recorded in Supplemental Identification, Evaluation, and Finding of Effect for Additional Proposed Demolition at U12g Tunnel, Area 12, Nevada national Security Site, Nye County, Nevada (Brannan et al. 2024). Identification efforts indicated that the two buildings and Storage Area 1 supported nuclear testing in the U12g Tunnel. Storage Area 1 and Storage Area 2 post-dated the nuclear testing activities at U12g Tunnel and were not recommended as contributing elements to the district. The report also found that the undertaking would have an adverse effect on the newly identified buildings and one storage area and on the historic district. The SHPO concurred that the expanded undertaking would result in adverse effects to historic properties (Reed 2025). To resolve these adverse effects, NNSA/NFO, in consultation with the SHPO, is following standard mitigation as stipulated in the 2024 Programmatic Agreement DE-GM58-22NA25554 Among the U.S. Department of Energy and the Nevada State Historic Preservation Officer and the Advisory Council on Historic Preservation Concerning the Protection of Historic Properties on the Nevada National Security Site, Nye County, Nevada (hereafter referred to as the NNSS PA). The standard mitigation measures are outlined in Appendix D of the NNSS PA. As such, this architectural survey has been prepared in accordance with Appendix D of the NNSS PA and follows the report format outlined in Appendix F. It includes a historic context that describes the district’s origin, history, and support functions, its significance in the context of nuclear testing on the NNSS, and identifies contributing and non-contributing elements within the district. The report is accompanied by Architectural Resource Assessment (ARA) forms for individual resources and a Historic District Resource Assessment (HDRA) for the U12g Tunnel Historic District. In total, this architectural report identified 32 primary resources within the district boundary. Six of the primary resources were previously identified as contributing elements. An additional 17 resources are recommended as contributing elements to the district for a total of 23 contributing elements. The other nine resources identified are recommended as non-contributing elements to the district.

12-201800↗
DOE OSTI2026

Applied Research and Development to Support Open-Water Testing at PacWave

This report presents the findings from Task 7 of the project, which focused on improving the performance and reliability of wave energy converters (WECs) under real-world conditions, particularly in the presence of marine growth (biofouling) and system faults. The work was conducted using the RM3 point absorber WEC model, a marine current turbine based on the SHARKS project model, and the WEC-Sim simulation platform, and it included both modeling and control system development.

16 TIDAL AND WAVE POWER↗
DOE OSTI2025

Evaluation of Damage in Medium Voltage Cable Using Machine Learning

Developments in cable test instrumentation coupled with artificial intelligence and machine learning (ML) to aid in interpretation of cable test signals supports the feasibility for automated analysis of reflectometry tests for low voltage power cables. This work seeks to leverage prior ML work and success for low voltage cables to evaluate potential application to medium voltage (2kV to 10kV) installations. The Accelerated and Real-Time Environmental Nodal Assessment (ARENA) Cable Motor Test Bed at Pacific Northwest National Laboratory (PNNL) was used to test a medium voltage cable with several types of damage including thermal aging and low resistance conductor-to-shield faults. The cable was tested using an inductive clamshell coupler to protect the test instruments from the energized cable voltages that would damage the test instruments if coupled directly to the energized conductor.

42 ENGINEERING↗
DOE OSTI2020

Support of the Development of EPP Plus SMT Design Method (FY2020 Test Results)

Experiments in support of the development of the integrated Elastic–Perfectly Plastic (EPP) analysis and Simplified Model Test (SMT) design methodology continued in FY 2020. The previously developed single-bar SMT (SBSMT) technique was successfully extended to tubular shaped Alloy 617 specimens for evaluation of the effect of primary pressure load on SMT creep-fatigue (CF) properties at 950°C. A series of pressurized SMT tests were performed with various elastic follow-up factors and strain ranges. The results show that the primary pressure load reduces the SMT CF cycles. The reduction of SMT CF life due to primary load was found to be dependent on strain ranges, elastic follow up and test temperatures. These results are crucial for verification of the EPP strain range analysis in the EPP+SMT evaluation procedure. Additionally, hold time effect on the SMT CF life cycles is a determining factor for generating the EPP+SMT CF design curves. Lack of test data in the high cycle and low strain range region results in major uncertainty in developing the design curves. In FY2020, experiments were designed, and testing started on Alloy 617 at 950°C to fill the gap in experimental data. The on-going CF and additional SMT CF with elastic follow-up at low strain ranges will generate the information needed to verify the methods for extrapolation to long hold time and finalize the EPP+SMT design method.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Flow Sensor Test Article (F-STAr) (Design and Fabrication Status Report)

The Flow Sensor Test Article (F-STAr) is a test article currently under construction for the Mechanisms Engineering Test Loop (METL). F-STAr was designed to provide high sodium flowrate capabilities for sensor calibration, component testing, and fluid studies. Figure 1 shows two solid model views of the new test article. F-STAr includes a high-capacity pump that can provide a nominal flowrate of 120 GPM; a test section support structure that can accommodate a wide array of sub-test articles and their instrumentation; and finally, a heating and cooling system to aid in controlling the testing environment. Initially, F-STAr will be configured to test liquid metal flow sensors, specifically field shift sensors like the Eddy Current Flow Sensors (ECFS) based on the RDT C4-7T standard. To test these sensors, two test sections were designed that attempt to model Sodium Fast Reactor (SFR) outlet conditions. Figure 2 shows models of the “Full-Scaled Test Section” (FSTS) that represents a generic SFR fuel handling socket and a “Pseudo-Scaled Test Section” (PSTS) that represents a generic array of scaled fuel handling sockets. While F-STAr will be configured to test ECFS’s, it can also be outfitted to meet other experimental needs. For example, F-STAr could be setup with a test section that includes a fluidic diode or a component test investigating the performance of hydrodynamic bearings. Other test sections include studies of sodium thermal hydraulics like thermal striping. Overall, F-STAr is a flexible test article designed to accommodate many needs. This report will provide a status update on the design and construction of F-STAr. Manufacturing of all components has commenced, and several components have already been completed. These components include the pump and test section assembly stand. Other components, such as the heater, have been completed but were rejected due to the vendor not meeting the requirements of the purchase order. Lastly, the submersible flowmeter and main flange components are under construction, and their status will be reviewed in this report. Overall, most of the F-STAr components and parts will be completed by the end of September 2022.

42 ENGINEERING↗
DOE OSTI2020

Evaluation of Multi-cell Failure Propagation

Failure propagation testing is of increasing interest to the designers and end users of battery systems. One of the chief difficulties, however, is choosing an appropriate initiation method to perform the test. Single cell abuse testing is typically used to initiate thermal runaway but this can involve a large amount of additional energy injected into the system. It is assumed that this will have some impact on the behavior of a propagating thermal runaway event, but there is little data available as to how significant this would be. Further, it is ultimately difficult to develop viable propagation tests for compliance and public safety activities without better knowledge of how test methods will impact the results. This work looks at propagating battery failure with a variety of chemistries, formats, configurations and initiation methods to determine the level of significance of the chosen initiation method on the test results. We have ultimately found while there is some impact on the detailed results of propagation testing, in most cases other factors, particularly the energy density of the system play a much greater role in the likelihood of a propagation event consuming an entire battery. We have also provided some guidelines for test design to support best practices in testing.

25 ENERGY STORAGE↗
DOE OSTI2021

Gimballed Tracking Mount Pointing Angle Qualification

Tonopah Test Range (TTR), in support of its testing mission and modernization effort acquired a fleet of new gimballed tracking mounts (GTMs) manufactured by BAE Systems. The new GTMs can be operated remotely during flight tests and provide near real-time target tracking data. Furthermore, test vehicle Time-Space-Position-Information (TSPI) is evaluated using post-test synchronized imagery and pointing angle measurements acquired from each tracking mount. To comply with the Nuclear Enterprise Assurance Program (NEAP), all measurements devices must be certified. In keeping with the NEAP program, qualification of the new GTMs have been assessed to confirm that their pointing angle measurements produce acceptable TSPI results. This study only evaluated the four GTMs as a stand-alone solution and found that the GTMs meet their performance requirement of 0.006 degrees RMS error (or less) for post-processed pointing angles and produced TSPI solution with error volumes on the order of one meter or less. The new GTMs will be utilized in combination with existing optical tracking mounts, which will only improve the accuracy of the resulting TSPI data product. Details regarding the approach, analysis, summary results, and conclusions are presented.

42 ENGINEERING↗
DOE OSTI2020

Adaptive Recovery Model: Designing Systems for Testing Tracing and Vaccination to Support COVID-19 Recovery Planning.

This report documents a new approach to designing disease control policies that allocate scarce testing, contact tracing, and vaccination resources to better control community transmission of COVID19 or similar diseases. The Adaptive Recovery Model (ARM) combines a deterministic compartmental disease model with a stochastic network disease propagation model to enable us to simulate COVID-19 community spread through the lens of two complementary modeling motifs. ARM contact networks are derived from cell-phone location data that have been anonymized and interpreted as individual arrivals to specic public locations. Modeling disease spread over these networks allows us to identify locations within communities conducive to rapid disease spread. ARM applies this model- and data-derived abstractions of community transmission to evaluate the effectiveness of disease control measures including targeted social distancing, contact tracing, testing and vaccination. The architecture of ARM provides a unique capacity to help decision makers understand how best to deploy scarce testing, tracing and vaccination resources to minimize disease-spread potential in a community. This document details the novel mathematical formulations underlying ARM, presents a dynamical stability analysis of the deterministic model components, a sensitivity analysis of control parameters and network structure, and summarizes a process for deriving contact networks from cell-phone location data. An example use case steps through applying ARM to evaluate three targeted social distancing policies using Bernalillo County, New Mexico as an exemplar test locale. This step-by-step analysis demonstrates how ARM can be used to measure the relative performance of competing public health policies. Initial scenario tests of ARM shows that ARMs design focus on resource utilization rather than simple incidence prediction can provide decision makers with additional quantitative guidance for managing ongoing public health emergencies and planning future responses.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2024

Load Test of Alum-a-Lift Serial No. 33053261

An Alum-A-Lift A800CSPD-60 (Lift) was procured to support mechanical testing of programmatic equipment. This testing will take place within the Bldg. 131 Hi Bay. The design of the Lift procured for the purposes at LLNL was a modification of a machine that had previously been engineered and sold by Alum-a-Lift, see Fig. 1. The modification was to shorten the boom from a 56 in. length to a 28 in. length. The modified design is illustrated in Fig. 2. The Lift was fabricated and shipped to LLNL, received ~ June 2022. Upon arrival, it was successfully evaluated for “no-load” performance capability. Upon inspection of the documentation provided by Alum-a-Lift, it was noted that the load test was performed to qualify the machine for a lifting capacity of 200 lb. The LLNL requirement was that the capacity of the machine be 400 lb. Conversations with the vendor, Alum-A-Lift, followed this discovery. Rather than send the machine back to the vendor for load testing, discussions concurred that LLNL would load test the machine and Alum-A-Lift would provide the relevant load test placard to be placed on the machine subsequent to the successful load test. This MESN provides documentation of the load test to qualify the Alum-a-Lift to its’ rated capacity of 400 lb.

42 ENGINEERING↗