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NASA NTRS2013

Next-Generation Lightweight Mirror Modeling Software

The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond machining of glasses and ceramics has created the need for more efficient means of generating finite element models of these structures. Traditional methods of assembling 400,000 + element models can take weeks of effort, severely limiting the range of possible optimization variables. This paper will introduce model generation software developed under NASA sponsorship for the design of both terrestrial and space based mirrors. The software deals with any current mirror manufacturing technique, single substrates, multiple arrays of substrates, as well as the ability to merge submodels into a single large model. The modeler generates both mirror and suspension system elements, suspensions can be created either for each individual petal or the whole mirror. A typical model generation of 250,000 nodes and 450,000 elements only takes 5-10 minutes, much of that time being variable input time. The program can create input decks for ANSYS, ABAQUS and NASTRAN. An archive/retrieval system permits creation of complete trade studies, varying cell size, depth, and petal size, suspension geometry with the ability to recall a particular set of parameters and make small or large changes with ease. The input decks created by the modeler are text files which can be modified by any editor, all the key shell thickness parameters are accessible and comments in deck identify which groups of elements are associated with these parameters. This again makes optimization easier. With ANSYS decks, the nodes representing support attachments are grouped into components; in ABAQUS these are SETS and in NASTRAN as GRIDPOINT SETS, this make integration of these models into large telescope or satellite models possible

Arnold, William R., Sr.↗

NASA NTRS2013

Next Generation Lightweight Mirror Modeling Software

Arnold, William R., Sr.↗

DOE OSTI2018

Development of Creep-Resistant, Alumina-Forming Ferrous Alloys for High-Temperature Structural Use

This paper overviews recent advances in developing novel alloy design concepts of creep-resistant, alumina-forming Fe-base alloys, including both ferritic and austenitic steels, for high-temperature structural applications in fossil-fired power generation systems. Protective, external alumina-scales offer improved oxidation resistance compared to chromia-scales in steam-containing environments at elevated temperatures. Alloy design utilizes computational thermodynamic tools with compositional guidelines based on experimental results accumulated in the last decade, along with design and control of the second-phase precipitates to maximize high-temperature strengths. The alloys developed to date, including ferritic (Fe-Cr-Al-Nb-W base) and austenitic (Fe-Cr-Ni-Al-Nb base) alloys, successfully incorporated the balanced properties of steam/water vapor-oxidation and/or ash-corrosion resistance and improved creep strength. Development of cast alumina-forming austenitic (AFA) stainless steel alloys is also in progress with successful improvement of higher temperature capability targeting up to ~1100°C. Current alloy design approach and developmental efforts with guidance of computational tools were found to be beneficial for further development of the new heat resistant steel alloys for various extreme environments.

Yamamoto, Yukinori↗

DOE OSTI2021

FY2020 Materials Annual Progress Report

The Materials Technology subprogram supports the Vehicle Technologies Office’s (VTO’s) mission to accelerate the deployment of clean energy technology toward achieving net-zero emissions in the transportation sector. The Propulsion Materials research portfolio seeks to develop higher performance materials that can withstand increasingly extreme environments and address the future properties needed for a variety of high-efficiency powertrain types, sizes, fueling concepts, and combustion modes. The Lightweight Materials research portfolio enables improvements in fuel economy by providing properties that are equal to or better than traditional materials at a lower weight. Because it takes less energy to accelerate a lighter object, replacing cast-iron (Fe) and traditional steel components with lightweight materials—such as advanced high-strength steels (AHSS), magnesium (Mg) alloys, aluminum (Al) alloys, and fiber-reinforced polymer composites—can directly reduce a vehicle’s fuel consumption. By 2025, the Materials Technology research activities seek to enable a 25% weight reduction of the glider for light-duty (LD) vehicles including body, chassis, and interior as compared to a 2015 baseline at no more than a $5/lb-saved increase in cost.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Effects of Surface Treatments on the Outgassing of 3D-Printed 316L Stainless Steel.

Fermi National Accelerator Laboratory (Fermilab) is a world leader in designing and operating particle accelerators for nuclear and particle physics research. These accelerators rely on electric fields to propel particle beams, which are then directed and focused using magnetic fields. To ensure these beams travel without interference, they must move through an ultra-high vacuum environment, typically around 10⁻⁹ torr. Maintaining such a vacuum requires materials with exceptionally low outgassing rates. 316L stainless steel is a common material choice for vacuum systems due to its low outgassing rates, excellent corrosion resistance, non-magnetic properties, and high mechanical strength. When manufactured using traditional methods like machining, extrusion, and casting, the vacuum properties of 316L stainless steel are well understood. However, the behavior of 316L stainless steel produced through additive manufacturing, such as Direct Metal Laser Sintering (DMLS), is not as well documented. This study aims to determine the outgassing rate of 316L stainless steel fabricated using DMLS. The investigation focuses on measuring the outgassing rates of 1.5 2 vacuum reducers and evaluating the effects of surface preparation techniques, such as mechanical polishing and electropolishing, on the outgassing performance. Understanding the outgassing performance of 3D-printed 316L stainless steel could enable Fermilab engineers to adopt this fabrication method for producing complex parts designed for ultra-high vacuum environments. These advancements have the potential to benefit projects, such as the Long-Baseline Neutrino Facility (LBNF) and the Proton Improvement Plan-II (PIP-II), by improving design flexibility and fostering innovation in accelerator development.

Cloud, Jaiden [Central State University]↗

NASA NTRS1992

An incremental strategy for calculating consistent discrete CFD sensitivity derivatives

In this preliminary study involving advanced computational fluid dynamic (CFD) codes, an incremental formulation, also known as the 'delta' or 'correction' form, is presented for solving the very large sparse systems of linear equations which are associated with aerodynamic sensitivity analysis. For typical problems in 2D, a direct solution method can be applied to these linear equations which are associated with aerodynamic sensitivity analysis. For typical problems in 2D, a direct solution method can be applied to these linear equations in either the standard or the incremental form, in which case the two are equivalent. Iterative methods appear to be needed for future 3D applications; however, because direct solver methods require much more computer memory than is currently available. Iterative methods for solving these equations in the standard form result in certain difficulties, such as ill-conditioning of the coefficient matrix, which can be overcome when these equations are cast in the incremental form; these and other benefits are discussed. The methodology is successfully implemented and tested in 2D using an upwind, cell-centered, finite volume formulation applied to the thin-layer Navier-Stokes equations. Results are presented for two laminar sample problems: (1) transonic flow through a double-throat nozzle; and (2) flow over an isolated airfoil.

Korivi, Vamshi Mohan↗

NASA NTRS2003

Jet Propulsion Laboratory: Annual Report 2002

The year 2002 brought advances on many fronts in our space exploration ventures. A new orbiter settled in at Mars and delivered tantalizing science results suggesting a vast store of water ice under the planet's surface, a discovery that may have profound consequences for exploring Mars. A long-lived spacecraft made its final fly-bys of Jupiter's moons, while another started its final approach toward Saturn and yet another flew by an asteroid on its way to a comet. A new ocean satellite began science observations, joined in Earth orbit by a pair of spacecraft measuring our home planets gravity field, as well as JPL instruments on NASA and Japanese satellites. A major new infrared observatory and a pair of Mars rovers were readied for launch. All told, JPL is now communicating with 14 spacecraft cast like gems across the velvet expanses of the solar system. It is a far cry from the early 1960's, when JPL engineers made prodigious efforts to get the first planetary explorers off the ground and into space - an achievement of which we were especially mindful this year, as 2002 marked the 40th anniversary of the first successful planetary mission, Mariner 2, which barely reached our closest planetary neighbor, Venus. Added to this anniversary were celebrations surrounding the 25th anniversaries of the launches of Voyagers 1 and 2, two remarkable spacecraft that are still flying and are actively probing the outer realms of the solar system. These events of the past and present provide an occasion for reflection on the remarkable era of exploration that we at the Jet Propulsion Laboratory are privileged to be a part of. As 2002 neared its end, the Laboratory had yet another reason for celebration, as a new five-year management contract between NASA and the California Institute of Technology was signed that calls for a closer working relationship with NASA and other NASA centers as a member of the 'One NASA' team. There is a strong emphasis on cost control and management, areas in which we can improve, enabling us to become more competitive. This new agreement again confirms NASA's trust and faith in Caltech and JPL, in which we should all take great pride. If the history of JPL were a book, we are on the verge of turning the page to one that promises to be one of the most exciting and busiest chapters in JPL's history. In 2003 and 2004, we will launch 11 spacecraft or major payloads. We will land two rovers on Mars; put a spacecraft in orbit around Saturn, deliver a probe to the surface of its largest moon, Titan, and map Titan's surface withimaging radar; send a spacecraft past a comet collecting samples from its tail, while another one is launched toward a comet impact; bring a capsule back to Earth with the first samples ever collected beyond the orbit of the Moon; map the skies in the ultraviolet as well as the infrared spectrum to unprecedented accuracy; and continue the mapping of ocean topography and winds on our home planet, Earth.

National Aeronautics and Space Administration (NAS↗

DOE OSTI2024

A Cast of Thousands: How the IDEAS Productivity Project Has Advanced Software Productivity and Sustainability

Computational and data-enabled science and engineering are revolutionizing advances throughout science and society, at all scales of computing. For example, teams in the U.S. Department of Energy’s Exascale Computing Project have been tackling new frontiers in modeling, simulation, and analysis by exploiting unprecedented exascale computing capabilities—building an advanced software ecosystem that supports next-generation applications and addresses disruptive changes in computer architectures. However, concerns are growing about the productivity of the developers of scientific software. Members of the Interoperable Design of Extreme-scale Application Software project serve as catalysts to address these challenges through fostering software communities, incubating and curating methodologies and resources, and disseminating knowledge to advance developer productivity and software sustainability. This article discusses how these synergistic activities are advancing scientific discovery—mitigating technical risks by building a firmer foundation for reproducible, sustainable science at all scales of computing, from laptops to clusters to exascale and beyond.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Volumetric Rendering on Wavelet-Based Adaptive Grid

Numerical modeling of physical phenomena frequently involves processes across a wide range of spatial and temporal scales. In the last two decades, the advancements in wavelet-based numerical methodologies to solve partial differential equations, combined with the unique properties of wavelet analysis to resolve localized structures of the solution on dynamically adaptive computational meshes, make it feasible to perform large-scale numerical simulations of a variety of physical systems on a dynamically adaptive computational mesh that changes both in space and time. Volumetric visualization of the solution is an essential part of scientific computing, yet the existing volumetric visualization techniques do not take full advantage of multi-resolution wavelet analysis and are not fully tailored for visualization of a compressed solution on the wavelet-based adaptive computational mesh. Our objective is to explore the alternatives for the visualization of time-dependent data on space-time varying adaptive mesh using volume rendering while capitalizing on the available sparse data representation. Two alternative formulations are explored. The first one is based on volumetric ray casting of multi-scale datasets in wavelet space. Rather than working with the wavelets at the finest possible resolution, a partial inverse wavelet transform is performed as a preprocessing step to obtain scaling functions on a uniform grid at a user-prescribed resolution. As a result, a solution in physical space is represented by a superposition of scaling functions on a coarse regular grid and wavelets on an adaptive mesh. An efficient and accurate ray casting algorithm is based just on these coarse scaling functions. Additional details are added during the ray tracing by taking an appropriate number of wavelets into account based on support overlap with the interpolation point, wavelet coefficient magnitude, and other characteristics, such as opacity accumulation (front to back ordering) and deviation from frontal viewing direction. The second approach is based on complementing of wavelet-based adaptive mesh to the traditional Adaptive Mesh Refinement (AMR) mesh. Both algorithms are illustrated and compared to the existing volume visualization software for Rayleigh-Benard thermal convection and electron density data sets in terms of rendering time and visual quality for different data compression of both wavelet-based and AMR adaptive meshes.

Vezolainen, Alexei V.↗

NASA NTRS2003

The X-ray Microcalorimeter Spectrometer (XMS): A Reference Cryogenic Instrument Design for Constellation-X

Constellation-X, a mission now belonging to the Beyond Einstein initiative, is being planned to inherit the x-ray sky from Chandra, XMM-Newton and Astro-E. The first two of four observatories in the constellation will be launched together in 2013 and followed a year later by the launch of the remaining two. The four will independently orbit the Sun-Earth Lagrange point L2. An instrument compliment resides in the Focal Plane Module (FPM) of each observatory 10 m from the Optics Module and consists of three Hard X-ray Telescope (HXT) detectors, a Reflection Grating Spectrometer (RGS) focal plane CCD camera and an X-ray Microcalorimeter Spectrometer (XMS). Instrument awards are scheduled for early 2006. The reference detector for XMS is a 32 x 32 array of microcalorimetric superconducting Transition Edge Sensors (TES). Each pixel casts a variable resistance in a SQUID based multiplexed readout circuit which is coupled to series SQUID arrays for amplification and finally read out by external electronics. A multi-stage continuous ADR will provide the stable 50 mK desired for the TES array and a stable 1 K for the series SQUID arrays while also lifting thermal parasitic and inefficiency loads to a 6 K cryocooler interface. The 6 K cryocooler is expected to emerge from the joint-project Advanced Cryocooler Technology Development Program (ACTDP) in which Constellation-X is an active participant. Project Pre-Formulation activities are marked by extensive technology development necessitating early, but realistic, thermal and cooling load requirements for ADR and ACTDP-cryocooler design points. Such requirements are driven by the encompassing XMS cryostat and ultimately by the thermal environment imposed by the FPM. It is further desired that the XMS instrument be able to operate on its side in the laboratory, with a warm vacuum shell, during an extensive calibration regime. It is that reference system design of the XMS instrument (microcalorimeter, ADR, cryocooler and cryostat) which is the subject of this paper.

Whitehouse, Paul L.↗

NASA NTRS2003

A Tabletop Tool for Modeling Life Support Systems

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations.

Ramachandran, N.↗

NASA NTRS2005

Space Laboratory on a Table Top: A Next Generative ECLSS design and diagnostic tool

This paper describes the development plan for a comprehensive research and diagnostic tool for aspects of advanced life support systems in space-based laboratories. Specifically it aims to build a high fidelity tabletop model that can be used for the purpose of risk mitigation, failure mode analysis, contamination tracking, and testing reliability. We envision a comprehensive approach involving experimental work coupled with numerical simulation to develop this diagnostic tool. It envisions a 10% scale transparent model of a space platform such as the International Space Station that operates with water or a specific matched index of refraction liquid as the working fluid. This allows the scaling of a 10 ft x 10 ft x 10 ft room with air flow to 1 ft x 1 ft x 1 ft tabletop model with water/liquid flow. Dynamic similitude for this length scale dictates model velocities to be 67% of full-scale and thereby the time scale of the model to represent 15% of the full- scale system; meaning identical processes in the model are completed in 15% of the full- scale-time. The use of an index matching fluid (fluid that matches the refractive index of cast acrylic, the model material) allows making the entire model (with complex internal geometry) transparent and hence conducive to non-intrusive optical diagnostics. So using such a system one can test environment control parameters such as core flows (axial flows), cross flows (from registers and diffusers), potential problem areas such as flow short circuits, inadequate oxygen content, build up of other gases beyond desirable levels, test mixing processes within the system at local nodes or compartments and assess the overall system performance. The system allows quantitative measurements of contaminants introduced in the system and allows testing and optimizing the tracking process and removal of contaminants. The envisaged system will be modular and hence flexible for quick configuration change and subsequent testing. The data and inferences from the tests will allow for improvements in the development and design of next generation life support systems and configurations. Preliminary experimental and modeling work in this area will be presented. This involves testing of a single inlet-exit model with detailed 3-D flow visualization and quantitative diagnostics and computational modeling of the system.

Ramachandran, N.↗

DOE OSTI2018

Biomimetic model-based advanced control strategy integrated with multi-agent optimization for nonlinear chemical processes

Here, a novel framework is proposed for integrating biomimetic-based advanced control and multi-agent optimization approaches for nonlinear chemical process applications. In particular, a Biologically-Inspired Optimal Control Strategy, denoted as BIO-CS, is combined with multi-agent optimization (MAO) techniques to provide optimal solutions for dynamic systems. In this combined framework, the BIO-CS algorithm employs gradient-based optimal control solvers for the intermediate problems associated with the leader-follower agents’ local interactions. Also, the MAO uses the capabilities of heuristic-based optimization techniques by sharing process information to obtain optimal operating setpoints for the controller considering an overall process objective. The applicability of the proposed method is demonstrated using a nonlinear, multivariable, process model of a fermentation system. Specifically, the optimal operating points are computed by the MAO implementation for setpoint tracking, trajectory tracking and plant-model mismatch scenarios for BIO-CS application. Results of the developed framework are compared to a gradient-based Sequential Quadratic Programming (SQP) technique and a classical proportional-integral (PI) controller in terms of optimization and control studies, respectively. As an additional contribution, BIO-CS is also cast as a model predictive controller (MPC) for the first time and compared to the agent-based BIO-CS approach in terms of computational time and tracking error. Closed-loop control results show up to 46% improvement in tracking performance during transient for the multi-agent BIO-CS when compared to BIO-CS as MPC for additional computational expense. The obtained results illustrate the capabilities of this novel integrated framework including BIO-CS as MPC to achieve desired nonlinear system performance for various scenarios.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2019

ISEP: A Joint SRAG/CCMC Collaboration to Improve Mitigation of Space Weather Effects on Crew Health in the Exo-LEO Era

The Space Radiation Analysis Group (SRAG) at Johnson Space Center (JSC) is tasked with monitoring changes to space weather and mitigating any resultant impacts to crew health and safety. As human spaceflight goals extend from Low-Earth Orbit (LEO) missions like the International Space Station (ISS) to the moon, Mars and beyond, SRAG will need to update their current approach for crew monitoring of and protection from radiation exposure due to energetic Solar Particle Events (ESPEs). Challenges faced in planning exo-LEO missions include the lack of protection from the Earth’s geomagnetic field employed by the ISS in addition to limited communication capability between the crew and the ground. In the event of an ESPE, the current ISS trajectory ensures that the vehicle is only traveling through fields of higher radiation exposure for a brief period of time; the Earth’s geomagnetic field prevents the penetration of the high-energy particles of concern throughout the majority of the orbit. Exo-LEO missions, on the other hand, require that the vehicle travel through free space, exposing vehicle and crew to the full impact of the ESPE. NASA has combined multiple approaches to resolve this radiation exposure issue. New vehicles are designed to take advantage of advances in particle transport modeling capabilities and shielding technology, allowing redistribution of mass throughout the vehicle to areas of thinner shielding when the energetic particle flux has increased to levels of concern. Although vehicle shielding is an important aspect of radiation exposure protection, there is a continued requirement to monitor and predict the space weather environment. To this end, SRAG maintains a console position in Mission Control with 24/7 mission support capability. In the event of increased solar activity, SRAG collaborates with the Flight Control Team (FCT) to determine if crew action (i.e., shelter) is required. During any increase in solar activity, the FCT needs three pieces of information to effectively decide the crew response in light of other required mission tasks: if an event (ESPE) will occur, how ‘intense’ an observed event will be, and how long will an observed event will last. An ideal alert system limits false alarms, therefore causing the crew to take action unnecessarily, without ignoring events that pose a hazard to the crew. SRAG’s current operational concept for ISS missions focuses on short-term forecasts, best described as ‘now-casting’. Console operators are in daily communication with the Space Weather Prediction Center (SWPC) for situational awareness purposes. When conditions exist that may lead to increased solar activity, operators receive notifications from SWPC. In the case of a well-connected ESPE, the console operator may only have on the order of minutes to several hours to notify the FCT of the event and provide a recommendation for crew action. As NASA shifts to exo-LEO missions, the increased time in free space as well as the reduced ability to communicate with the crew will force a transition in crew protection strategy that emphasizes improvments to both the accuracy and the lead time in forecasting capabilities.

Barzilla, Janet E.↗

NASA NTRS1993

NASA's Advanced solid rocket motor

The Advanced Solid Rocket Motor (ASRM) will not only bring increased safety, reliability and performance for the Space Shuttle Booster, it will enhance overall Shuttle safety by effectively eliminating 174 failure points in the Space Shuttle Main Engine throttling system and by reducing the exposure time to aborts due to main engine loss or shutdown. In some missions, the vulnerability time to Return-to-Launch Site aborts is halved. The ASRM uses case joints which will close or remain static under the effects of motor ignition and pressurization. The case itself is constructed of the weldable steel alloy HP 9-4-0.30, having very high strength and with superior fracture toughness and stress corrosion resistance. The internal insulation is strip-wound and is free of asbestos. The nozzle employs light weight ablative parts and is some 5,000 pounds lighter than the Shuttle motor used to date. The payload performance of the ASRM-powered Shuttle is 12,000 pounds higher than that provided by the present motor. This is of particular benefit for payloads delivered to higher inclinations and/or altitudes. The ASRM facility uses state-of-the-art manufacturing techniques, including continuous propellant mixing and direct casting.

Mitchell, Royce E.↗

DOE OSTI2021

Advanced Ultra-Supercritical Component Test (ComTest) Project for 760*C Steam Conditions

ComTest is a $27M Department of Energy-funded project. Phase I, which began in November 2015, served to identify the technology gaps, as well as the scope and cost of required testing. Phase II, which was awarded in December 2018, includes an advanced manufacturing effort to complete U.S. based supply chain development for full commercial scale (800-850 MWe) AUSC components made of nickel-based alloys, components operating at up to 760°C. Completion of Phase II scheduled for September 30, 2021. Strategic Objectives of U.S. AUSC Project include: Power Plant Efficiency Improvements –Develop cost-effective, reliable technologies to improve the efficiency of new and existing high-temperature advanced generation power plants. Close gaps to achieve readiness for commercial scale demonstration of Advanced Ultra-Supercritical (AUSC) technology. Fabricate full-scale versions of key nickel-based alloy components. Validate capabilities of US supply chain for cost certainty. Support cross-cutting high-temperature generation technologies. Obtain ASME Code approval for new materials, components and processes. Increase power plant steam temperatures for higher cycle efficiency (Note: Average efficiency of US coal-fired fleet = 33% HHV; A-USC plant efficiency over 47% HHV at 1,400°F (760°C) steam temperature).

fireside corrosion↗

DOE OSTI2025

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9, 435, 011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9,435,011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

36 MATERIALS SCIENCE↗