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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 901 records · Page 50

OVERVIEW OF RECENT PU-238 PRODUCTION ACTIVITIES AT IDAHO NATIONAL LABORATORY

The Plutonium Fuel Services (PFS) program at Idaho National Laboratory (INL) is active in the qualification of irradiation targets containing Np-237 for irradiation in the Advanced Test Reactor (ATR) to produce Pu-238 for future NASA missions. INL qualified and loaded 7 targets in ATR’s South Flux Trap (SFT) for cycle 169A, which occurred in Spring 2021. This program was reinitiated after two baseline production targets in three positions validated significant production of Pu-238 [ref.1]. The validation model was followed by the PFS-1 experimental test in the ATRC (Critical) facility [ref.2]. This paper outlines the progress and status of the PFS program. The qualification effort, safety analysis, hardware status, and future activities for qualification of an updated target design for use in the ATR will be discussed.

36 MATERIALS SCIENCE↗

Aerodynamic characteristics of the 40- by 80/80- by 120-foot wind tunnel at NASA Ames Research Center

The design and testing of vane sets and air-exchange inlet for the 40 x 80/80 x 120-ft wind tunnel at NASA Ames are reported. Boundary-layer analysis and 2D and 3D inviscid panel codes are employed in computer models of the system, and a 1/10-scale 2D facility and a 1/50-scale 3D model of the entire wind tunnel are used in experimental testing of the vane sets. The results are presented in graphs, photographs, drawings, and diagrams are discussed. Generally good agreement is found between the predicted and measured performance.

Corsiglia, V. R.↗

Aerodynamic characteristics of the 40- by 80-/80- by 120-ft wind tunnel at NASA-Ames Research Center

The design and testing of vane sets and air-exchange inlet for the 40 x 80/80 x 120-ft wind tunnel at NASA Ames are reported. Boundary-layer analysis and 2D and 3D inviscid panel codes are employed in computer models of the system, and a 1/10-scale 2D facility and a 1/50-scale 3D model of the entire wind tunnel are used in experimental testing of the vane sets. The results are presented in graphs, photographs, drawings, and diagrams and discussed. Generally good agreement is found between the predicted and measured performance.

Corsiglia, V. R.↗

Percolation in Salt Rocks - 18652

We present laboratory investigations of fluid percolation in salt rocks, performed on drilled core samples, which show that natural rock salt does not become permeable at high pressures and temperatures, as had been claimed in the literature. Rather, we confirm the existence of a percolation threshold: Fluid migration is only possible when the fluid pressure equals or exceeds the lowest confining stress. The lab tests corroborate in-situ-determinations of the percolation threshold in salt formations: The threshold is given by the minimal stress in the rock mass (minimal stress criterion), and fluid pressure-driven percolation starts once it is exceeded. The hypothesis that the percolation threshold vanishes at high pressure and temperature is thus refuted by experiments on natural rock salt. These experimental tests, performed in the framework of the KOSINA project, are an important prerequisite for the proof of integrity of saliferous barriers in the disposal of radioactive waste in salt rocks. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

An Eulerian multimaterial framework for simulating high-explosive aquarium tests

Aquarium tests of cylindrical high-explosive charges provide optical data of the detonation front velocity and shape, propagation of the shock wave in the surrounding water, and expansion rates of the detonation products behind the front. Data from aquarium experiments is often used for calibration of reactive burn models based on phenomenological equations of state (EOS) and reaction rate laws. This paper presents a multimaterial numerical modeling framework to solve the 2D axisymmetric reactive Euler equations for high-explosive aquarium tests, in particular for ammonium nitrate - fuel oil (ANFO) explosives. An extension of the Ghost Fluid Method (GFM) is used to handle the dynamic material interfaces for the ANFO explosion products, the charge-confining material (polymethyl methacrylate PMMA), and the surrounding water. This study analyzes the sensitivity of calculations (both computational efficiency and numerical accuracy) to different algorithms for the material interface models including the original GFM versus Riemann solver-based strategies. A novel method for defining the left and right states in the interfacial Riemann problem eliminates the need for sorting or nodal interpolation during the projection along the material interface. Numerical tests indicate that populating the interface node values using the Riemann solution mitigate the overheating error observed in steady-state calculations. Solution convergence and computational efficiency are explored as a function of the spatial and temporal order of the schemes. Results from the computational model with analytical equations of state and fitted reaction rate parameters show very good quantitative agreement with experimentally observed detonation front velocity, reaction products expansion, and shock wave propagation in the surrounding water for a cylindrical ANFO charge encased in PMMA. Finally, the proposed modeling framework, in conjunction with experimental tests, provides a reliable tool to assess equations of state and reaction rate expressions for reactive burn models of confined high explosives.

42 ENGINEERING↗

Unveiling Carbon Ring Structure Formation Mechanisms in Polyacrylonitrile-Derived Carbon Fibers

As the demand for electric vehicles (EVs) and autonomous vehicles (AVs) rapidly grows, lower-cost, lighter, and stronger carbon fibers (CFs) are urgently needed to respond to consumers’ call for greater EV traveling range and stronger safety structures for AVs. Converting polymeric precursors to CFs requires a complex set of thermochemical processes; a systematic understanding of each parameter in fiber conversion is still, to a large extent, lacking. Here, we demonstrate the effect of carbonization temperature on carbon ring structure formation by combining atomistic/microscale simulations and experimental validation. Experimental testing, as predicted by simulations, exhibited that the strength and ductility of PAN CFs decreased, whereas the Young’s modulus increased with increasing carbonization temperature. Our simulations unveiled that high carbonization temperature accelerated the kinetics of graphitic phase nucleation and growth, leading to the decrease in strength and ductility but increase in modulus. The methodology presented herein using combined atomistic/microscale simulations and experimental validation lays a firm foundation for further innovation in CF manufacturing and low-cost alternative precursor development.

36 MATERIALS SCIENCE↗

Crashworthiness Models for Automotive Batteries

Safety is a key element of any device designed to store energy, particularly of electrochemical batteries, which convert energy of chemical reactions to electrical energy. Safety considerations are especially important when applied to large automotive batteries designed for propulsion of electric vehicles (EV). The high amount of energy stored in EV battery packs translates to higher probability of fire in case of severe deformation of battery compartment due to automotive crash or impact caused by road debris. While such demand for safety has resulted in heavier protection of battery enclosure, the mechanisms leading to internal short circuit due to deformation of the battery are not well understood even on the level of a single electrochemical cell. Moreover, not all internal shorts result in thermal runaway, and thus a criterion for catastrophic failure needs to be developed. This report summarizes the effort to pinpoint the critical deformation necessary to trigger a short via experimental study on large format automotive Li-ion cells subjected to large deformations as those occurring in deformation of battery module or pack. Mechanical properties of cell components were determined via experimental testing and served as input for constitutive models of Finite Element (FE) analysis. It has been rationalized that long-range stress fields occurring in spherical indentation of battery modules would trigger different deformation and failure scenarios compared to indentation of a single cell supported by a rigid flat surface. In order to investigate large deformations characteristic of battery module, a custom experimental set up has been built where the pouch cell was deformed against a compliant backing, which was represented by a ballistic clay. Experiments were also conducted on deformation of stacks of 10 pouch cells, - configuration representing half-module in Ford Focus EV battery pack without cooling plates and structural components. Comparison of the results shows promise for the compliant backing setup for safety evaluation of battery cells under more realistic conditions compared to indentation of single cell against undeformable backing where compression and electrode particle penetration through separator could be the major mechanism for short circuit.

25 ENERGY STORAGE↗

Associated with aerospace vehicles development of methodologies for the estimation of thermal properties

Thermal stress analyses are an important aspect in the development of aerospace vehicles at NASA-LaRC. These analyses require knowledge of the temperature distributions within the vehicle structures which consequently necessitates the need for accurate thermal property data. The overall goal of this ongoing research effort is to develop methodologies for the estimation of the thermal property data needed to describe the temperature responses of these complex structures. The research strategy undertaken utilizes a building block approach. The idea here is to first focus on the development of property estimation methodologies for relatively simple conditions, such as isotropic materials at constant temperatures, and then systematically modify the technique for the analysis of more and more complex systems, such as anisotropic multi-component systems. The estimation methodology utilized is a statistically based method which incorporates experimental data and a mathematical model of the system. Several aspects of this overall research effort were investigated during the time of the ASEE summer program. One important aspect involved the calibration of the estimation procedure for the estimation of the thermal properties through the thickness of a standard material. Transient experiments were conducted using a Pyrex standard at various temperatures, and then the thermal properties (thermal conductivity and volumetric heat capacity) were estimated at each temperature. Confidence regions for the estimated values were also determined. These results were then compared to documented values. Another set of experimental tests were conducted on carbon composite samples at different temperatures. Again, the thermal properties were estimated for each temperature, and the results were compared with values obtained using another technique. In both sets of experiments, a 10-15 percent off-set between the estimated values and the previously determined values was found. Another effort was related to the development of the experimental techniques. Initial experiments required a resistance heater placed between two samples. The design was modified such that the heater was placed on the surface of only one sample, as would be necessary in the analysis of built up structures. Experiments using the modified technique were conducted on the composite sample used previously at different temperatures. The results were within 5 percent of those found using two samples. Finally, an initial heat transfer analysis, including conduction, convection and radiation components, was completed on a titanium sandwich structural sample. Experiments utilizing this sample are currently being designed and will be used to first estimate the material's effective thermal conductivity and later to determine the properties associated with each individual heat transfer component.

Scott, Elaine P.↗

Inflatable Antenna for CubeSat: Extension of the Previously Developed S-Band Design to the X-Band

The inflatable antenna for CubeSat is a 1 meter antenna reflector designed with one side reflective Mylar, another side clear Mylar with a patch antenna at the focus. The development of this technology responds to the increasing need for more capable communication systems to allow CubeSats to operate autonomously in interplanetary missions. An initial version of the antenna for the S-Band was developed and tested in both anechoic chamber and vacuum chamber. Recent developments in transceivers and amplifiers for CubeSat at X-band motivated the extension from the S-Band to the X-Band. This paper describes the process of extending the design of the antenna to the X-Band focusing on patch antenna redesign, new manufacturing challenges and initial results of experimental tests.

Babuscia, Alessandra↗

An Advanced Meso-Scale Peridynamic Modeling Technology using High-Performance Computing for Cost-Effective Product Design and Testing of Carbon Fiber Reinforced Polymer Composites in Light-weight Vehicles

We study a peridynamic composite modeling technology based on the discontinuous Galerkin finite element method, implemented in the commercial LS-DYNA software, for modeling and prediction of failure in carbon fiber reinforced polymer composites. The proposed technology is developed for the material failure analysis at the meso-scale, which provides the prevailing fiber-matrix interaction mechanism, without adoption of the representative volume element method and thus avoiding complicated numerical calibration procedures. Three types of experimental tests—in-plane coupon test, out-of-plane coupon test, and a component crash test—are simulated in a high-performance computing environment to assess the performance of the proposed peridynamic composite modeling technology.

36 MATERIALS SCIENCE↗

Liquid Acquisition Device Testing with Sub-Cooled Liquid Oxygen

When transferring propellant in space, it is most efficient to transfer single phase liquid from a propellant tank to an engine. In earth s gravity field or under acceleration, propellant transfer is fairly simple. However, in low gravity, withdrawing single-phase fluid becomes a challenge. A variety of propellant management devices (PMD) are used to ensure single-phase flow. One type of PMD, a liquid acquisition device (LAD) takes advantage of capillary flow and surface tension to acquire liquid. Previous experimental test programs conducted at NASA have collected LAD data for a number of cryogenic fluids, including: liquid nitrogen (LN2), liquid oxygen (LOX), liquid hydrogen (LH2), and liquid methane (LCH4). The present work reports on additional testing with sub-cooled LOX as part of NASA s continuing cryogenic LAD development program. Test results extend the range of LOX fluid conditions examined, and provide insight into factors affecting predicting LAD bubble point pressures.

Jurns, John M.↗

SINFAC simulation of a high-power hybrid CPL

The systems improved numerical fluids analysis code (SINFAC) was used to model a high-power hybrid capillary-pumped loop. A comparison was made between the simulation results and actual experimental test data for the mechanical-pump-assist mode of operation. The hybrid capillary-pumped loop consisted of a capillary-pumped loop with a mechanical pump in the liquid return line with a bypass value so that the system could be operated either as a capillary-only loop or a series hybrid loop. Excellent agreement was obtained between numerical and experimental data.

Benner, Steve M.↗

Implementation of atomic layer etching of silicon: Scaling parameters, feasibility, and profile control

Atomic or layer by layer etching of silicon exploits temporally segregated self-limiting adsorption and material removal steps to mitigate the problems associated with continuous or quasicontinuous (pulsed) plasma processes: selectivity loss, damage, and profile control. Successful implementation of atomic layer etching requires careful choice of the plasma parameters for adsorption and desorption steps. This paper illustrates how process parameters can be arrived at through basic scaling exercises, modeling and simulation, and fundamental experimental tests of their predictions. Using chlorine and argon plasma in a radial line slot antenna plasma source as a platform, the authors illustrate how cycle time, ion energy, and radical to ion ratio can be manipulated to manage the deviation from ideality when cycle times are shortened or purges are incomplete. Cell based Monte Carlo feature scale modeling is used to illustrate profile outcomes. Experimental results of atomic layer etching processes are illustrated on silicon line and space structures such that iso-dense bias and aspect ratio dependent free profiles are produced. Experimental results also illustrate the profile control margin as processes move from atomic layer to multilayer by layer etching. The consequence of not controlling contamination (e.g., oxygen) is shown to result in deposition and roughness generation.

42 ENGINEERING↗

A machine learning approach to thermal conductivity modeling: A case study on irradiated uranium-molybdenum nuclear fuels

A deep neural network was developed for the purpose of predicting thermal conductivity with a case study performed on irradiated nuclear fuel. Traditional thermal conductivity modeling approaches rely on existing theoretical frameworks that describe known, relevant phenomena that govern the microstructural evolution processes during neutron irradiation (such as recrystallization, and pore size, distribution and morphology). Current empirical modeling approaches, however, do not represent all irradiation test data well. We develop a machine learning approach to thermal conductivity modeling that does not require a priori knowledge of a specific material microstructure and system of interest. Our approach allows re-searchers to probe dependency of thermal conductivity on a variety of reactor operating and material conditions. The purpose of building such a model is to allow for improved predictive capabilities linking structure-property-processing-performance relationships in the system of interest (here, irradiated nuclear fuel), which could lead to improved experimental test planning and characterization. The uranium-molybdenum system is the fuel system studied in this work, and historic irradiation test data is leveraged for model development. Our model achieved a mean absolute percent error of approximately 10%. Results indicate our model generalizes well to never before seen data, and thus use of deep learning methods for material property predictions from limited, historic irradiation data is a viable approach. This work challenges the current paradigm in materials science, where material property models are based on limited experimental data fitted to low-dimensionality phenomenological models, or by simulations in which fundamental equations are explicitly solved. The work presented here aims to demonstrate the potential and limitations of machine learning in the field of materials science and material property modeling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

3D printed structures for optimized carbon capture technology in packed bed columns

The use of 3D printed structured packing for the optimization of aqueous-amine based carbon capture in packed absorption columns is examined in this paper. An experimental testing system has been set up, and initial comparisons were made between metal, plastic, and 3D printed 16-inch packing elements and between three 8-inch 3D printed elements of different densities. Pressure drop measurements were obtained at various air flowrates under dry conditions. Measurements were also taken for a wet system by adding water at six different liquid flowrates. In each case, theoretical calculations for pressure drop were performed based on a model presented in the literature. It was found that, for the 16-inch dry column, the model slightly overpredicts the pressure drop. The model provides an accurate prediction for the dry 8-inch experimental data, especially for the two least dense packing elements. For the wet system, the model overpredicts the pressure drop, likely due to modeling deficiencies when the column reaches its loading limit. Furthermore, these results provide sufficient confidence to move forward with testing and process intensification of the CO 2 capture process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A micromechanics model for bread dough

The mechanical behaviour of dough and gluten was studied in an effort to investigate whether bread dough can be treated as a two phase (starch and gluten) composite material. The dough and gluten show rate dependent behaviour under tension, compression and shear tests, and non-linear unloading-reloading curves under cyclic compression tests. There is evidence from cryo-Scanning Electron Microscopy (SEM) that damage in the form of debonding between starch and gluten occurs when the sample is stretched. A composite finite element model was developed using starch as filler and gluten as matrix. The interaction between the starch and gluten was modelled as cohesive contact. The finite element analysis predictions agree with trends seen in experimental test data on dough and gluten, further evidence that debonding of starch and gluten is a possible damage mechanism in dough.

36 MATERIALS SCIENCE↗

PECAN2

PECAN2, Pose Classification with 3D Atomic Network 2, presents an innovative approach to pose classification in computational modeling, particularly in the context of molecular docking. Traditional methods like docking, which rely on physics-based calculations, are prone to inaccuracies in predicting binding poses during experimental testing. While machine learning (ML) approaches, such as ML-driven pose classification, have been introduced to address these issues, they often depend on the availability of crystal structure data. In contrast, PECAN2 introduces a novel pose classification method that operates independently of crystal structures. Instead, it utilizes a 3D atomic neural network with Point Cloud Network (PCN) to establish correlations between docking scores and experimental data. This approach marks a departure from previous studies that heavily relied on crystal structures for labeling. The key innovation lies in the ability of PECAN2 to enhance the performance of molecular docking by filtering out false positives and false negatives through the correlation between docking scores and experimental data.

Shim, Heesung↗

Use of an inertial navigation system for accurate track recovery and coastal oceanographic measurements

A data acquisition system using a Litton LTN-51 inertial navigation unit (INU) was tested and used for aircraft track recovery and for location and tracking from the air of targets at sea. The characteristic position drift of the INU is compensated for by sighting landmarks of accurately known position at discrete time intervals using a visual sighting system in the transparent nose of the Beechcraft 18 aircraft used. For an aircraft altitude of about 300 m, theoretical and experimental tests indicate that calculated aircraft and/or target positions obtained from the interpolated INU drift curve will be accurate to within 10 m for landmarks spaced approximately every 15 minutes in time. For applications in coastal oceanography, such as surface current mapping by tracking artificial targets, the system allows a broad area to be covered without use of high altitude photography and its attendant needs for large targets and clear weather.

Oliver, B. M.↗