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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 1,045 records · Page 58
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Binder Jet Additive Manufacturing Process and Material Characterization for High Temperature Heat Exchangers Used in Concentrated Solar Power Applications

The U.S. Department of Energy’s (DOE) Sunshot 2030 initiative has a goal of reducing the cost of concentrating solar power (CSP) to 5 cents per kWh for baseload power plants. One of the potential pathways to this goal includes a reduction in the cost of the supercritical CO2 (sCO2) power block to 0.9 cents per kWh. Recuperators—high and low temperatures, used in the sCO2 power cycle, contribute to >50% of the cost of the power cycle. This work studies the feasibility towards a ≥10% cost reduction for High Temperature Recuperators (HTR) used in the sCO2 power cycle. One way to address the cost reduction is by leveraging low-cost additive manufacturing, specifically, Binder Jet Additive Manufacturing (BJAM) to 3D print HTRs at scale. This study focuses on the development of a BJAM process towards 3D printing HTR cores using Stainless Steel alloy 316L (SS316L). To evaluate the suitability of the BJ process towards the HTR, high level specifications of the application are translated to materials capability requirements. Subsequently, at-temperature materials testing is conducted on as-printed and sintered additively manufactured coupons. Data from the coupons are compared against cast and wrought SS316L data obtained from the literature. Results show that the tensile properties from the BJ process compare well against cast properties. Furthermore, a baseline analysis of creep testing data is established for the BJ process, and insights are drawn from the results towards future improvements of the process.

14 SOLAR ENERGY↗
NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This pa- per provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗
NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This paper provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗
NASA NTRS1988

A method for rapid liquid-solid phase solubility measurements using the protein lysozyme

Using hen's egg white lysozyme crystals as the test material, a simple system was developed for rapidly and unambiguously determining solubilities in (aqueous) solutions. The system is based upon a maximization of the solid surface area available for solute transfer to or from the solution, and a minimization of both the solution volume which must be equilibrated and the distance over which diffusive solute exchange occurs. This technique is further enhanced by using duplicate test systems which differ only in that one approaches equilibrium from an oversaturated solution, while the other from an undersaturated solution. Thus, the resulting data pair brackets the solubility value. In practical terms, the data points are found to usually be within 3 percent of each other, and individual solubility data points may usually be made at this resolution within 8-24 h depending upon the temperature change made since the previous determination.

Pusey, Marc L.↗
DOE OSTI2015

SU-E-J-136: Investigation Into Robustness of Stopping Power Calculated by DECT and SECT for Proton Therapy Treatment Planning

Purpose: To investigate the robustness of dual energy CT (DECT) and single energy CT (SECT) proton stopping power calibration techniques and quantify the associated errors when imaging a phantom differing in chemical composition to that used during stopping power calibration. Methods: The CIRS tissue substitute phantom was scanned in a CT-simulator at 90kV and 140kV. This image set was used to generate a DECT proton SPR calibration based on a relationship between effective atomic number and mean excitation energy. A SECT proton SPR calibration based only on Hounsfield units (HUs) was also generated. DECT and SECT scans of a second phantom of known density and chemical composition were performed. The SPR of the second phantom was calculated with the DECT approach (SPR-DECT),the SECT approach (SPR-SECT) and finally the known density and chemical composition of the phantom (SPR-ref). The DECT and SECT image sets were imported into the Pinnacle{sup 3} research release of proton therapy treatment planning. The difference in dose when exposed to a common pencil beam distribution was investigated. Results: SPR-DECT was found to be in better agreement with SPR-ref than SPR- SECT. The mean difference in SPR for all materials was 0.51% for DECT and 6.89% for SECT. With the exception of Teflon, SPR-DECT was found to agree with SPR-ref to within 1%. Significant differences in calculated dose were found when using the DECT image set or the SECT image set. Conclusion: The DECT calibration technique was found to be more robust to situations in which the physical properties of the test materials differed from the materials used during SPR calibration. Furthermore, it was demonstrated that the DECT and SECT SPR calibration techniques can Result in significantly different calculated dose distributions.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2013

Field Testing of Low-Cost Bio-Based Phase Change Material

A test wall built with phase change material (PCM)-enhanced loose-fill cavity insulation was monitored for a period of about a year in the warm-humid climate of Charleston, South Carolina. The test wall was divided into various sections, one of which contained only loose-fill insulation and served as a control for comparing and evaluating the wall sections with the PCM-enhanced insulation. This report summarizes the findings of the field test.

loose-fill insulation↗
DOE OSTI2016

Single crystal CVD diamond membranes for betavoltaic cells

A single crystal diamond large area thin membrane was assembled as a p-doped/Intrinsic/Metal (PIM) structure and used in a betavoltaic configuration. When tested with a 20 keV electron beam from a high resolution scanning electron microscope, we measured an open circuit voltage (V{sub oc}) of 1.85 V, a charge collection efficiency (CCE) of 98%, a fill-factor of 80%, and a total conversion efficiency of 9.4%. These parameters are inherently linked to the diamond membrane PIM structure that allows full device depletion even at 0 V and are among the highest reported up to now for any other material tested for betavoltaic devices. It enables to drive a high short-circuit current I{sub sc} up to 7.12 μA, to reach a maximum power P{sub max} of 10.48 μW, a remarkable value demonstrating the high-benefit of diamond for the realization of long-life radioisotope based micro-batteries.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2017

Crack Growth Testing of an Aluminum Oxynitride (AlON) for International Space Station Kick Panes

The mechanical properties of an aluminum oxynitride supplied as ground beams and disks were measured using ASTM International (formerly American Society for Testing and Materials) standard test methods. The slow crack growth tests were complicated by a "short" finish that increased strength scatter. Refining of the finish by more material removal in the second stage of grinding or the use of uniaxial grinding as specified in ASTM C1499 might have avoided the issue. The structural design parameters are an elastic modulus of E = 319 GPa, Poisson's ratio of v = 0.26, a fracture toughness of KIvb(A) = 2.18 MPa/m, slow crack growth (SCG) parameter n = 36, and SCG parameter A = 1.96 x 10-11 m/s.(MPa/m)n. For a ground finish, the Weibull parameters are a mean modulus of m = 14.0 and characteristic strength of sigma theta = 250.2 MPa. The 2015 vintage material exhibits similar mechanical properties to a 2010 vintage billet. Indentation flaws were not sensitive to the inherent crack growth mechanisms of this material and produced misleading results.

strength↗
DOE OSTI2015

Correlating the chemical composition and size of various metal oxide substrates with the catalytic activity and stability of as-deposited Pt nanoparticles for the methanol oxidation reaction

The performance of electrode materials in conventional direct alcohol fuel cells (DAFC) is constrained by (i) the low activity of the catalyst materials relative to their overall cost, (ii) the poisoning of the active sites due to the presence of partially oxidized carbon species (such as but not limited to CO, formate, and acetate) produced during small molecule oxidation, and (iii) the lack of catalytic stability and durability on the underlying commercial carbon support. Therefore, as a viable alternative, we have synthesized various metal oxide and perovskite materials of different sizes and chemical compositions as supports for Pt nanoparticles (NPs). Our results including unique mechanistic studies demonstrate that the SrRuO 3 substrate with immobilized Pt NPs at its surface evinces the best methanol oxidation performance as compared with all of the other substrate materials tested herein, including commercial carbon itself. In addition, data from electron energy loss spectroscopy (EELS) and X-ray photoelectron spectroscopy (XPS) confirmed the presence of electron transfer from bound Pt NPs to surface Ru species within the SrRuO 3 substrate itself, thereby suggesting that favorable metal support interactions are responsible for the increased methanol oxidation reaction (MOR) activity of Pt species with respect to the underlying SrRuO 3 composite catalyst material.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

An Improved Pathway to Ethylene Glycol via CO 2

This report describes our efforts to develop a partial electrochemical oxidation process to produce formaldehyde selectively from methanol. The effort examined numerous potential anode materials in pursuit of 70% Faradaic efficiency for conversion of methanol to formaldehyde. Among the various electrode materials tested herein both Pt and PtRu were identified as the most promising catalysts in this process as the Faradaic efficiency obtained in these cases are 40% and >70% respectively. Several other 3d transition metals, Pt group metals and their alloys were also studied in which the Faradaic efficiency was obtained within 5-30%. In case of Pt and PtRu bulk metal electrode shows higher selectivity to formaldehyde compared to their nanostructured materials. Based on the literature, nanostructured Pt and PtRu are considered as active catalysts for methanol fuel cells, thus, lower selectivity to formaldehyde with nano Pt and PtRu in our case was attributed to their preferential oxidation of methanol to CO 2 . Severe catalyst deactivation was noted when 0.5 (M) sulfuric acid was used as the electrolyte irrespective of catalyst formulation. On the other hand, much higher activity and selectivity for formaldehyde was noted when alkaline electrolyte was employed during oxidation. Considering selective electrochemical oxidation of methanol to formaldehyde is an area which is underexplored as of today, our findings about catalyst formulation and process condition is noteworthy in this direction. Both bulk metal electrodes of Pt and PtRu may be cost prohibitive and thus present challenges to the scale up this technology. Therefore, we recognize that additional efforts are needed to develop catalysts with high activities and Faradaic efficiencies similar to bulk electrodes for the electrooxidation of methanol to formaldehyde.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRSDate not supplied

Modeling the Uptake of Hydrogen Chloride onto Interior Spacecraft Materials

Hydrogen chloride (HCl) is a major combustion product from the pyrolysis of polyvinyl chloride (PVC) insulated electrical wires, a common spacecraft fire safety concern. Models at two different scales were developed to predict HCl uptake on anodized, chromate conversion coated (Iridite), and bare aluminum surfaces, as well as on Nomex fabric: a macroscopic one-step global surface reaction model where all the active sites are on the exterior surface, and a pore model where the interior active sites deeper into the oxide layer can also be accessed by HCl. Experiments were performed to calibrate kinetic and diffusion constants in the models. A cast acrylic test cell was used to measure the differences between the inlet and outlet concentration of HCl after inserting a sample rod of the test material. For the materials with a thin (< 200 µm) or no oxide layer, the macroscopic surface reaction model adequately predicts the experimental measurements. For the anodized aluminum with a thicker oxide layer, the pore model provided a better match to experimental results. The results will be discussed with respect to the spacecraft fire safety project (Saffire).

modeling↗
DOE OSTI2016

Considerations of the Differences between Bedded and Domal Salt Pertaining to Disposal of Heat-Generating Nuclear Waste

Salt formations hold promise for eternal removal of nuclear waste from our biosphere. Germany and the United States have ample salt formations for this purpose, ranging from flat-bedded formations to geologically mature dome structures. As both nations revisit nuclear waste disposal options, the choice between bedded, domal, or intermediate pillow formations is once again a contemporary issue. For decades, favorable attributes of salt as a disposal medium have been extoled and evaluated, carefully and thoroughly. Yet, a sense of discovery continues as science and engineering interrogate naturally heterogeneous systems. Salt formations are impermeable to fluids. Excavation-induced fractures heal as seal systems are placed or natural closure progresses toward equilibrium. Engineering required for nuclear waste disposal gains from mining and storage industries, as humans have been mining salt for millennia. This great intellectual warehouse has been honed and distilled, but not perfected, for all nuances of nuclear waste disposal. Nonetheless, nations are able and have already produced suitable license applications for radioactive waste disposal in salt. A remaining conundrum is site location. Salt formations provide isolation, and geotechnical barriers reestablish impermeability after waste is placed in the geology. Between excavation and closure, physical, mechanical, thermal, chemical, and hydrological processes ensue. Positive attributes for isolation in salt have many commonalities independent of the geologic setting. In some cases, specific details of the environment will affect the disposal concept and thereby define interaction of features, events and processes, while simultaneously influencing scenario development. Here we identify and discuss high-level differences and similarities of bedded and domal salt formations. Positive geologic and engineering attributes for disposal purposes are more common among salt formations than are significant differences. Developing models, testing material, characterizing processes, and analyzing performance all have overlapping application regardless of the salt formation of interest.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Mechanical Loads on Spent Nuclear Fuel in the General 30 cm Package Drop Scenario

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Spent Fuel and Waste Science & Technology (SFWST) research program is guided by the high-level goal of closing prioritized knowledge gaps related to spent nuclear fuel (SNF) storage and transportation, which are summarized by Saltzstein et al. (2020). One of the high-priority knowledge gaps is the identification and quantification of mechanical loads that are expected to affect SNF during normal conditions of transportation and storage to inform the range of physical SNF test programs. This report uses modeling and analysis methods to estimate the mechanical loads on spent nuclear fuel (SNF) in the general 30 cm package drop scenario. The drop scenario assumes impact limiters are in place in the transportation configuration and the impact surface is perfectly rigid. The goal of this analysis is to consider the universe of potential mechanical loading conditions that can happen to SNF and present the results in a manner that is useful for materials testing, decision making, and regulatory rule making purposes. This study uses validated finite element models and methods to perform a broad parametric study of key variables that can affect the mechanical loads on SNF during a hypothetical package free drop scenario. Physical drop test data from a cask and fuel assembly drop test campaign is the basis for model validation. Additionally, the results of the parametric study are used to inform a damage model, which uses multiple nonlinear regression to estimate the relationships between input variables and output response. The parametric finite element analyses consider thousands of input variable combinations, while the damage model estimates millions of combinations. The breadth of this study provides confidence that the potential range of mechanical loads that SNF might experience during the general 30 cm package drop scenario are characterized well enough to consider this knowledge gap closed. While this report documents the overall peak values calculated in this study, the 95 th percentile values, the histograms, and the observed trends are equally important. This study covered a large range of SNF temperatures, room temperature to 300°C, and burnups, 10 GWd/MTU to 62 GWd/MTU. Each temperature and burnup combination has a different cladding yield strain, so it is more meaningful to summarize the calculated cladding strain response as its factor of safety, which is defined relative to the yield strain. The factor of safety is calculated as the yield strain divided by the peak cladding strain. A factor of safety greater than unity indicates that the cladding remains below yield, whereas a value less than unity is indicative of plastic deformation. In all cases of this study a safety factor over 1.0 was calculated, although in the most limiting case at 300°C the safety factor was only 1.01, which suggests that yielding could occur when additional loads like rod internal pressure are included. When the temperature is restricted to 200°C the limiting safety factor increases to 1.28, which has significant margin to accommodate internal pressure and potential local cladding defects that could cause a local stress concentration. An important trend in the calculated fuel rod mechanical loads is that the 2 nd highest loaded fuel rod in an assembly tends to be significantly lower than the highest loaded rod. The implication is that even if one rod in an assembly experiences a failure the loads would have to be significantly higher to cause two or more rods to fail.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Compact Heat Exchanger Design and Testing for Advanced Reactors and Advanced Power Cycles

The goal of the proposed research is to demonstrate the thermal hydraulic performance of innovative surface geometries in compact heat exchangers used as intermediate heat exchangers (IHXs) and recuperators for the supercritical carbon dioxide (s-CO 2 ) Brayton cycle. Printed-circuit heat exchangers (PCHEs) are the primary compact heat exchangers of interest. The overall objectives are: To develop optimized PCHE designs for different working fluid combinations including helium to s-CO 2 , liquid salt to s-CO 2 , sodium to s-CO 2 , and liquid salt to helium; To experimentally and numerically investigate thermal performance, thermal stress and failure mechanism of PCHEs under various transients; and To study diffusion bonding techniques for elevated-temperature alloys and examine post-test material integrity of the PCHEs. The project objectives were accomplished by defining and executing five different tasks corresponding to these specific objectives. The first task involved a thorough literature review and a selection of IHX candidates with different surface geometries as well as a summary of prototypic operational conditions. The second task involved optimization of PCHE design with numerical analyses of thermal-hydraulic performances and mechanical integrity. The subsequent task dealt with the development of testing facilities and engineering design of PCHE to be tested in s-CO 2 fluid conditions. The next task involved experimental investigation and validation of the thermal-hydraulic performances and thermal stress distribution of prototype PCHEs manufactured with particular surface geometries. The last task involved an investigation of diffusion bonding process and posttest destructive testing to validate mechanical design methods adopted in the design process. The experimental work utilized the two test facilities at The Ohio State University (OSU) including one existing High-Temperature Helium Test Facility (HTHF) and the newly developed s-CO 2 test loop (STL) facility and s-CO 2 test facility at University of Wisconsin – Madison (UW).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Advanced Test Reactor Long-Term (20-Year) Operational Strategy

The Department of Energy Office of Nuclear Energy (DOE-NE) and the Naval Nuclear Propulsion Program (NNPP) have identified the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) as a critical need for continued thermal irradiation testing capability to support and advance U.S. commercial and naval nuclear power systems. The ATR is currently the only suitable test reactor operating in the world that can provide these capabilities at volume. ATR must, then, plan to operate for at least the next 20 years. As of the beginning of 2024, ATR has operated for 57 years, with many of the original reactor structures, systems, and components installed and operated for 60 years. Some ATR Complex and reactor support equipment that is currently in use was installed 75 years ago with the startup of the Materials Testing Reactor (MTR).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2007

RDS-21 Face-Gear Surface Durability Tests

Experimental fatigue tests were performed to determine the surface durability life of a face gear in mesh with a tapered spur involute pinion. Twenty-four sets of gears were tested at three load levels: 7200, 8185, and 9075 lb-in face gear torque, and 2190 to 3280 rpm face gear speed. The gears were carburized and ground, shot-peened and vibro-honed, and made from VIM-VAR Pyrowear 53 steel per AMS 6308. The tests produced 17 gear tooth spalling failures and 7 suspensions. For all the failed sets, spalling occurred on at least one tooth of all the pinions. In some cases, the spalling initiated a crack in the pinion teeth which progressed to tooth fracture. Also, spalling occurred on some face gear teeth. The AGMA endurance allowable stress for a tapered spur involute pinion in mesh with a face gear was determined to be 275 ksi for the material tested. For the application of a tapered spur involute pinion in mesh with a face gear, proper face gear shim controlled the desired gear tooth contact pattern while proper pinion shim was an effective way of adjusting backlash without severely affecting the contact pattern.

Lewicki, David G.↗
NASA NTRS1989

Materials compatibility with oxidizer-rich gases at elevated temperatures and pressure

An investigation of oxygen compatibility and resistance to ignition of candidate materials for use in a liquid rocket engine designed to incorporate an oxidizer rich preburner-LOX turbopump configuration was discussed. The program was divided into two basic tasks. The first task was to develop a preliminary design of an oxidizer turbopump preburner section complete with thermal and MS Parameter analyses and to develop a conceptual design of the main injector with a preliminary engine specification as the final product. The second task was directed totally at testing materials in oxygen-rich environments.

Source record↗