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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

An Artificial-Intelligence and Machine-Learning-Based Methodology to Conduct Seemingly Strain-Controlled Fatigue Test in a Pressurized-Water-Reactor-Test-Loop-Autoclave, While Not Controlling the Strain

In general, low cycle fatigue analysis of pressurized water reactor (PWR) components, requires strain-controlled fatigue test data such as using strain versus life (ε–N) curves. Conducting strain-controlled fatigue tests under in-air conditions is not an issue. However, controlling strain in a PWR-test-loop-autoclave is a challenge, since an extensometer cannot be placed in a narrow autoclave (typically used in a high-temperature-pressure PWR-test-loop). This is due to lack of space inside an autoclave that houses the test specimen. In addition, installing a contact-type extensometer in the path of a high-pressure flow can be a challenge. These difficulties of using an extensometer inside an autoclave led us to use an outside-autoclave displacement sensor which measures the displacement of pull-rod-specimen assembly. However, in our study (based on in-air fatigue test data), we found that a pull-rod-controlled based fatigue test can lead to substantial cyclic hardening/softening resulting in substantially different cyclic strain amplitudes and their rates compared to the desired cyclic strain amplitudes and its rates. In this paper, we propose an Artificial-Intelligence and Machine-Learning based technique such as using k-means clustering technique to improve the pull-rod-control based fatigue test method, such that the gage-area strain amplitude and rates can reasonably be achieved. In support of this, we present the fatigue test results for both 316 SS base and 81/182 dissimilar-metal-weld specimens.

42 ENGINEERING↗
DOE OSTI2018

Compensatory grazing by Daphnia generates a trade‐off between top‐down and bottom‐up effects across phytoplankton taxa

Abstract Trade‐offs among traits that shape different components of fitness determine the potential for species to coexist in communities and the regulation of ecosystem productivity by consumers vs. resources. We compared functional and structural traits of 14 species of freshwater phytoplankton to test the influence of life history (exponential growth rate, r, and asymptotic density, K), cell volume, cellular fatty acid ( FA ) biochemistry, and stoichiometry (cellular C:N and C:P ratios) on grazing and growth rate of Daphnia consumers. Grazers exerted the strongest top‐down effects on algae with the highest C:N and C:P, and lower levels of FA unsaturation. In contrast, the grazer's growth rate was most associated with phytoplankton species’ FA unsaturation and chain length. Different traits were related to grazing rate and trophic transfer efficiency, and as a result, the grazing rate on a particular phytoplankton taxon was unrelated to the grazers’ growth rate. The best nutrient competitors (those with high C:N, C:P, and K, which previous experiments showed had lower minimum requirements for nutrients) were most heavily affected by grazing, but did not contribute the most to grazer growth. Our results indicate that Daphnia increase their food consumption rate in order to compensate for low stoichiometric food quality. Strong competitors with low nutrient demands may therefore be subject to the most intense grazing by individual consumers but not support greater production of higher trophic levels.

Mandal, Shovon↗
DOE OSTI2022

Improved Creep and Tensile Properties of a Corrosion Resistant Ni-Based Superalloy Using High Temperature Aging and Nb/Ta Additions

Resistance to creep deformation is essential for cast and wrought Ni-based superalloys in next generation energy systems due to the considerable exposure times required at the operating temperature. Here the amount of precipitate strengthening was increased in variants to Inconel alloy 725 (IN725), a corrosion resistant alloy, to improve its elevated temperature mechanical strength. Additions of Nb or Ta coupled with a high temperature aging (HTA) heat treatment promoted the formation of γ" precipitates and grain boundary phases which led to significant increases in time to failure. The HTA increased the creep life of various alloy formulations as compared to the standard aging heat treatment with a maximum improvement of 371%. The Nb and Ta additions lowered the minimum creep rate (MCR) and had a similar effect on increasing creep life. The positive effect of the additions was more pronounced when coupled with the HTA which employed a higher temperature in the first step of the heat treatment to promote precipitate phase formation. The Ti/Al ratio was used to design alloys with preferential formation of ' or γ" precipitates. Compact morphology precipitates were formed in the alloys with a low Ti/Al ratio. While a low Ti/Al ratio was primarily associated with lower MCRs, the effect on the creep life was less evident than that of the HTA. By using additions of Nb or Ta and a HTA heat treatment, the creep life of IN725 for testing at 973 K (700 °C) and 483 MPa was improved by up to 256%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Exploiting Acoustic Anisotropy to Detect Recrystallization in a Ni Single Crystal Using Ultrasonic Nondestructive Inspection

Ultrasonic inspection was used to detect regions of recrystallization (RX) within a single crystal of Ni. RX can produce polycrystalline regions within single-crystal (SX) materials. Because RX regions act as initiator sites for failure by fatigue-crack growth in otherwise SX Ni-based superalloys, RX is an issue of direct concern for the service life of high-performance turbine blades. Detection and discrimination of RX regions in single-crystal materials are significant challenges for current nondestructive inspection technologies. The present study leverages the elastic anisotropy of single crystals, which produces acoustic anisotropy, to ultrasonically detect and characterize RX regions produced within single-crystal specimens. Single crystals of pure Ni were processed to create controlled regions of RX. These specimens were ultrasonically examined in an immersion tank using a high-resolution, polyvinylidene fluoride transducer to detect acoustic impedance changes across the boundaries between different crystals (i.e., grains) within the RX region. Data from time-of-flight and absolute peak amplitude measurements were used to create acoustic images that were compared against electron microscope images of the RX regions. The ultrasonic inspection technique described here successfully detected not only the locations of RX regions, but also the approximate sizes and shapes of the RX regions.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fatigue behavior and modeling for additive manufactured 304L stainless steel: The effect of surface roughness

The fatigue strength of additively manufactured metallic parts in their as-built surface condition is mainly dominated by the surface roughness. Post-processing is often inevitable to reduce surface roughness effects even though post-processing diminishes the main advantage of additive manufacturing, which is net-shaped direct-to-service production. This work investigates the underlying mechanisms responsible for fatigue failure of additively manufactured 304L stainless steel parts in as-built and machined/polished surface conditions. Both strain- and force-controlled, fully reversed fatigue tests were conducted to gain a comprehensive understanding of surface roughness effects on fatigue behavior. The sensitivity to surface roughness is shown to be dependent on the control mode, with stress-based fatigue tests showing greater sensitivity than strain-based fatigue tests. Moreover, the fatigue life estimation for as-built specimens was performed based on surface roughness parameters as well as the fatigue properties of the specimens in machined/polished surface condition of the material without using any fatigue data of specimens in as-built surface condition. Accordingly, the effect of surface roughness on the fatigue behavior could be estimated reasonably well in both strain-life and stress-life approaches.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Optimal Control of Biomass Feedstock Processing System Under Uncertainty in Biomass Quality

Planning of biorefinery operations is complicated by the stochastic nature of physical and chemical characteristics of biomass feedstock, such as, moisture level and carbohydrate content. Biomass characteristics affect the performance of the equipment which feed the reactor and the efficiency of the conversion process in a biorefinery. We propose a stochastic optimization model to identify a blend of feedstocks, inventory levels, and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor while meeting the requirements of the biochemical conversion process. We propose a sample average approximation (SAA) of the model, and develop an efficient algorithm to solve the SAA model. A feedstock preprocessing process consists of two-stage grinding and pelleting is used to develop a case study. Extensive numerical analysis are conducted which lead to a number of observations. Our main observation is that sequencing bales based on moisture level and carbohydrate content leads to robust solutions that improve processing time and processing rate of the reactor. We provide a number of managerial insights that facilitate the implementation of the model proposed. Note to Practitioners—This paper is motivated by the challenges faced in the bioenergy industry. The focus of this paper is on plants which use the biochemical conversion process to generate liquid fuels. It has been observed that variations in biomass characteristics, such as moisture content, cause variations in feeding of the system which lead to under-utilization of equipment. A requirement of biochemical conversion process is to maintain the carbohydrate content of biomass processed by the reactor, larger than a threshold. We propose a model that identifies the inventory levels and operating conditions of equipment to ensure a continuous flowing of biomass to the reactor. The goal is to improve equipment utilization while satisfying the requirements of the conversion process. The model is tested using real-life data. We found out that by sequencing bales based on moisture level and carbohydrate content, a plant can reduce variability in the system leading to improved system reliability, higher processing rates of the reactor, and higher throughput.

09 BIOMASS FUELS↗
DOE OSTI2021

Accelerated Creep Testing of Inconel 718 Using the Stepped Isostress Method (SSM)

This paper demonstrates the stepped isostress method (SSM); an accelerated creep test (ACT) for the rapid assessment of metallic materials. The SSM test is based on the time-temperature-stress superposition principle (TTSSP) where temperature and/or stress are step increased to accelerate the time-to-rupture. The SSM test has proven successful for the ACT of polymers and polymeric composites but has yet to be proven for metallic materials. In this study, new test matrix design rules for the SSM of metals are established based on deformation mechanism, time-temperature transformation, and time-temperature precipitation maps. A test matrix of SSM and conventional creep tests (CCTs) are executed for alloy Inconel 718 at 750°C (1382°F) with stress levels ranging from 100 to 350 MPa. Validation CCT data is gathered from the Japan National Institute of Material Science (NIMS). Material constants for the Sine-hyperbolic (Sinh) constitutive model are calibrated using the SSM data and employed to predict the conventional creep response. Here, when blindly compared to the CCT data, the SSM calibrated Sinh model can accurately predict the conventional creep response across logarithmic decades and thus accelerate the capture of conventional creep data. Fractography indicates ductile fracture by transgranular microvoid coalescence (TMVC) with the same fracture mode observed in both SSM and CCT specimens. Creep cavitation is indicated by the population, smoothness, and size of microvoids.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The impact of temperature, chlorides and sulfate-reducing bacteria on the corrosion of steel in soil

Here, this investigation aimed to study the corrosion performance of low-carbon steel in a soil environment at different temperatures. The steel specimens in the soil were treated at three temperatures: 5, 25 and 60°C. The specimens were embedded in chloride-free soil for 21 days, and then 3.5% (by weight) sodium chloride (NaCl) was added to the soil. The specimens were then kept in the chloride-contaminated soil for 54 days. The results of electrochemical experiments showed superior corrosion performance of the specimens at 60°C, which had the lowest corrosion activity, followed by the specimens at 5 and 25°C. The slow nature of the kinetics of the corrosion reactions at 5°C compared with that at ambient temperature was the reason for this improvement at 5°C. The lower number of microorganisms, including sulfate-reducing bacteria, in the soil at 60°C compared with that at the other temperatures was attributed to the lower corrosion activity of steel in the soil at 60°C compared with the corrosion activity of steel in the soil at other temperatures.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Processing Municipal Solid Waste for Conversion to Jet Fuel (Final Technical Report)

This final report describes the successful demonstration of AI‑assisted waste sorting and a novel pressurized solids feed system to enable conversion of non‑recyclable municipal solid waste to jet fuel under DOE Award DE‑EE0009265. Results include improved feedstock purity and variability reduction, lab‑scale testing, and technoeconomic and life‑cycle assessments.

09 BIOMASS FUELS↗
DOE OSTI2019

Surface Treatment of Powder-Bed Fusion Additive Manufactured Metals for Improved Fatigue Life

High-cycle fatigue (HCF) tests were conducted on samples fabricated by two powder-bed additive manufacturing techniques. Samples were tested with as-produced surfaces and after various non-contact surface improvement treatments. Ti-6Al-4V samples were made using both electron beam melting (EBM) and selective laser melting (SLM), while Inconel 625 was fabricated using SLM. Ti-6Al-4V was treated with a commercial chemically accelerated vibratory polishing process, with target material removal of approximately 200 µm from each surface for EBM samples and 100 µm for SLM samples. This technique led to increases in both the number of cycles before failure at a given loading condition and endurance limit (at 10{sup 7} cycles) compared to samples with as-produced surfaces. The results are interpreted as the reduction in elastic stress concentration factor associated with surface defects where fatigue cracks initiate. SLM 625 was treated with both an abrasive polishing method and laser surface remelting. Both methods led to improvements in surface roughness, but these did not lead to improvements in fatigue properties of SLM 625. For abrasive polished samples, the combination of improved measured surface roughness without fatigue property enhancement suggests that surface material is removed, but the roots of surface defects, where fatigue cracks initiate, were left intact. For laser treatment, the remelted surface layer retained a rapidly solidified microstructure that did not increase the number of cycles before crack initiation even though the surface was smoother compared to the surface prior to polishing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Phase Field Modeling of Corrosion for Design of Next-Generation Magnesium-Aluminum Vehicle Joints

In this study, WPI and its partners sought to understand galvanic corrosion in Mg-Al friction stir weld (FSW) joints. Unlike fusion welds, FSW is done in the solid state. This limits (but does not eliminate) the formation of brittle Al-Mg intermetallics, resulting in better joint strength and corrosion resistance. This study aimed to understand corrosion behavior of Mg-Al FSW joints by using a Cahn-Hilliard phase field electrochemistry model based on the work of Pongsaksawad et al. Its context challenge problem was an ultra-light door designed by Magna with 6061-Al sheet outer and ZEK100-Mg sheet inner panels, joined by an adhesive and FSW. Unlike most FSW joints, which weld through the softer material into the harder one, the Al sheet’s hem joint around Mg required the FSW tool to through the harder Al into the softer Mg, which was itself a challenge. Despite this challenge, PNNL succeeded in consistently making very strong FSW lap joints, by using a triflute tool and power control. Characterization showed mostly separate Al and Mg regions in the weld, usually with a hook protruding from Al into Mg, which likely contributed to high joint strength. Nanohardness mapping showed higher hardness in thin Mg swirls into the Al nugget, likely due to the intermetallics. The study used the industry standard SAE J2334 Cyclic Corrosion Test (CCT) to simulate corrosion conditions over the life of a vehicle, as well as linear polarization testing and ASTM G71 pitting corrosion testing. Corrosion reactions were: H 2 O + ½O 2 + 2e - → 2OH - at the Al cathode, and either Mg → Mg 2+ + 2e - or Mg + 2OH - → Mg(OH) 2 + 2e - at the Mg anode, with electron transfer through the joint. Mass loss increased with Al section length, supporting the hypothesis that galvanic corrosion in Al-Mg joints is limited by the cathodic reaction. Both pitting corrosion (first anode reaction) and hydroxide film formation (second reaction) were observed. The J2334 CCT test method was slightly modified, adding a chromium solution cleaning step after each week of corrosion testing, in order to remove Mg oxides and hydroxides and accurately measure mass loss over time. That said, FSW joints treated in this way did not did not exhibit significant reduction in lap shear strength of the joints vs. newly welded samples which had not undergone corrosion. Corrosion appeared to consist mainly of pitting in Mg in a way which did not directly affect the bond between the materials where the joints failed. A Cahn-Hilliard phase field model coupled with electrical potential described the electronically mediated galvanic corrosion electrochemical reactions described above in the four-component Al-Mg-H 2 O-(H 2 O+½O 2 ) system. This 2-D model successfully predicted Mg(OH)₂ formation at the anode in some circumstances, and Mg pitting corrosion in others, and showed the correct electric field directions in both cases. The model predicted Mg pit corrosion depth within a factor of two of measured pits.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Out-of-Pile Testing and Instrumentation Transient Water Irradiation System

Current initiatives to increase the burnup of conventional nuclear fuels past the approximate 62 GWd/t limit have been spurred on by direct savings to refueling and waste storage. The technical justification for a new license limit requires extensive qualification through experimental testing. Unlike beginning-of-life fuels, high-burnup fuels are more susceptible to fuel fragmentation, relocation, and dispersal (FFRD), therefore more data is needed to characterize fuels under key accident scenarios. The Transient Reactor Test Facility (TREAT) located at the Idaho National Laboratory has developed a testing apparatus architecture to test fuels and claddings at prototypic conditions. The Transient Water Irradiation System (TWIST) is the latest iteration of a testing device capable of conducting loss of coolant accidents (LOCAs) in TREAT. The Out-of-Pile Testing and Instrumentation TWIST (OPTI-TWIST) is an electrically heated device that is analogous to TWIST. OPTI-TWIST allows for detailed instrumentation and thermal-hydraulic characterization. TWIST ultimately aims to conduct the most advanced in-situ diagnostics to evaluate FFRD in a prototypic LOCA. Moreover, it will explore the phenomenological bifurcation of a decay-energy heat up driven LOCA and a stored-energy heat up driven LOCA. The instrumentation suite includes conventional thermocouples and pressure transducers in addition to an electro impedance sensor, an acoustic emission sensor, an optical pressure sensor, and an optical pyrometer. Characterizing these instruments in OPTI-TWIST eliminates complications of irradiation effects while preserving extreme thermal-hydraulic conditions. Finally, benchmarking both devices to a thermal-hydraulic code like the Reactor Excursion and Leak Analysis Program (RELAP)5-3D provides a unique opportunity for iteration. Pre-test predictions and post-test interpretations inform the physical designs, operational procedures, test conditions, and instrumentation types and positions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Physics-based Multiscale Additively Manufactured Superalloy Design for Optimized High Cycle Fatigue Life (Final Report)

The objectives of this project are to: (i) Gain fundamental understandings towards the microscopic damage mechanisms, as impacted by pertinent materials properties (e.g. stacking fault energy (SFE) and microstructure (e.g., grain size), leading to high-cycle fatigue (HCF) damage to AM Ni-based superalloy parts; (ii) Provide scientific insight into the effect of testing frequency on damage mechanisms and fatigue life of AM Ni-based superalloy parts under HCF regime, thereby establishing an appropriate correlation between accelerated testing and materials’ true service life; (iii) Devise an accurate, experimentally validated multiscale model across atomic, micro- and meso-scales, to predict the cyclic stress-strain responses and fatigue damage accumulation for AM Ni-based superalloys under various loading frequencies.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Gen 3 Particle Pilot Plant (G3P3) Life Cycle Management Plan (SAND report)

The National Solar Thermal Test Facility (NSTTF) at Sandia National Laboratories New Mexico (SNL/NM) developed this Life Cycle Management Plan (LCMP) to document its process for executing, monitoring, controlling and closing-out Phase 3 of the Gen 3 Particle Pilot Plant (G3P3). This plan serves as a resource for stakeholders who wish to be knowledgeable of project objectives and how they will be accomplished.

14 SOLAR ENERGY↗
DOE OSTI2020

Initial development of a method for correlating indentation test results to damage accumulation in high temperature structural materials

This report describes an experimental approach based on microindentation creep or relaxation tests for assessing the remaining creep life of a sample material. The objective for this experimental program is to complement the development of passively loaded in situ surveillance specimens. These surveillance specimens could be placed in future advanced reactors to assess the degradation of structural properties, primary creep and creep-fatigue life, when the material is exposed to actual reactor operating conditions. The specimens and the corresponding indentation test protocol could form the basis of a structural health monitoring program designed to ensure the safe continued operation of the component given the relatively unknown effect of the reactor coolant chemistry, radiation exposure, and other environmental effects on the material properties of the constituent structural materials.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Design, Manufacturing, Assembly, Testing, and Lessons Learned of the Prototype 650 MHz Couplers

Six 650 MHz high-power couplers will be integrated into the prototype High Beta 650 MHz (HB650) cryomodule for the PIP-II project at Fermilab. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life-cycle, including manufacturing, assembly, testing, conditioning and the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Testing at scale during the COVID-19 pandemic

Assembly and publication of the severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) genome in January 2020 enabled the immediate development of tests to detect the new virus. This began the largest global testing programme in history, in which hundreds of millions of individuals have been tested to date. The unprecedented scale of testing has driven innovation in the strategies, technologies and concepts that govern testing in public health. In this Review, we describe the changing role of testing during the COVID-19 pandemic, including the use of genomic surveillance to track SARS-CoV-2 transmission around the world, the use of contact tracing to contain disease outbreaks and testing for the presence of the virus circulating in the environment. Despite these efforts, widespread community transmission has become entrenched in many countries and has required the testing of populations to identify and isolate infected individuals, many of whom are asymptomatic. The diagnostic and epidemiological principles that underpin such population-scale testing are also considered, as are the high-throughput and point-of-care technologies that make testing feasible on a massive scale.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Shell Predictive Battery Life Models (SPBLM) [SWR-20-35]

Battery life models to predict the capacity fade and resistance growth of lithium-ion batteries from various manufacturers with different chemistries. The battery life model is trained on experimental test data, and accounts for calendar and cycling aging mechanisms as functions of cell environmental conditions and use. The battery life model is then used to predict capacity fade and resistance growth under any arbitrary aging scenario.

Smith, Kandler↗