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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

An Experimental Investigation of Heat Transfer for Supercritical Carbon Dioxide Cooling in a Staggered Pin Fin Array

Pin fin geometry in the trailing edge as turbulators in tur-bine blades has been a subject thoroughly researched for the past several decades. To improve the efficiency of turbomachinery, higher turbine inlet temperatures are necessary, introducing the need for internal cooling channel features, such as pin fin arrays. These solutions are necessary to avoid material failure at higher operating conditions by enhancing the heat transfer of the blade. Over the past decade, a shift toward applying supercritical carbon dioxide or sCO2 cycles has shown increased potential compared to the industry standard air cycles. Promising higher cycle ef¬ficiency, smaller footprints, and zero greenhouse gas emissions, sCO2 has become an attractive alternative to well-established air cycles. This alternative cycle introduces the need to re-visit the heat transfer capabilities of internal cooling geometries within this novel operating fluid environment. The first objective of this paper is to experimentally demonstrate the heat transfer charac-teristics of sCO2 as the secondary internal cooling fluid environ¬ment through testing a pin fin array in a closed loop at 200 bar and 400 Celsius inlet conditions, which stands well within the supercritical region of sCO2. Secondly, the experimental process aims to validate numerical simulation methodology for studying sCO2 environments for internal cooling of turbine blades in a matching pin fin geometry.

Wardell, Ryan J↗

Engineering & Microstructure Scale PIE Report on EBR-II X441A Metallic Fuel Pins for the MORPH Experiment

The objectives of this project are to increase fundamental understanding of irradiation induced metallic U-Pu-Zr fuel behavior and to obtain data needed for the development of irradiation models for metallic fuels in MARMOT. The requested metallic fuel pins are from the X441A experiment irradiated in Experimental Breeder Reactor (EBR)-II and will be provided by the PIs for the duration of the experiment. The purpose of the pins irradiated in the X441A assembly was to vary Zr composition and fuel slug diameter in order to provide data for the metallic fuel performance code “LIFEMETAL” [ANL-IFR-125]. The fuels of interest to this project are metallic fuels with several Zr compositions (in wt.%): U-19Pu-6Zr, U-19Pu-10Zr, and U-19Pu-14Zr, which were irradiated to a peak burnup of approximately 11 at.%. The cladding was the same for all three fuel pins (austenitic stainless steel D9), which allows investigation of fuel-cladding interaction (FCI) phenomena. Varying Zr content in fuel pins enables investigation of the effect of Zr on fuel restructuring and fuel-cladding compatibility. Engineering and microstructure scale PIE activities will be focused on investigation of fundamental aspect of fuel performance such as species diffusion and migration, fission product behavior, and constituent redistribution. Obtained microstructural information will be used as the basis for the development of MARMOT models of U-Pu-Zr fuel performance at the mesoscale. Experimental data obtained through this proposal will be used to provide this fundamental understanding which will serve as the foundation of the development of radiation models for U-Pu-Zr in MARMOT. It will also provide a starting point for the design of new experiments to provide data for the validation of these MARMOT models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fuel Performance Analysis of Fast Flux Test Facility MFF-3 and -5 Fuel Pins Using BISON with Post Irradiation Examination Data

Using the BISON fuel-performance code, simulations were conducted of an automated process to read initial and operating conditions from the Pacific Northwest National Laboratory (PNNL) database and reports, which contain metallic-fuel data from the Fast Flux Test Facility (FFTF) MFF Experiments. This work builds on previous modeling efforts involving 1977 EBR-II metallic fuel pins from experiments. Coupling the FFTF PNNL reports to BISON allowed for all 338 pins from MFF-3 and MFF-5 campaigns to be simulated. Each BISON simulation contains unique power and flux histories, axial power and flux profiles, and coolant-channel flow rates. Fission-gas release (FGR), fuel axial swelling, cladding profilometry, and burnup were all simulated in BISON and compared to available post-irradiation examination (PIE) data. Cladding profilometry, FGR, and fuel axial swelling simulation results for full-length MFF metallic pins were found to be in agreement with PIE measurements using FFTF physics and models used previously for EBR-II simulations. The main two peaks observed within the cladding profilometry were able to be simulated, with fuel-cladding mechanical interaction (FCMI), fuel-cladding chemical interaction (FCCI), and thermal and irradiation-induced creep being the cause. A U-Pu-Zr hot-pressing model was included in this work to allow pore collapse within the fuel matrix. This allowed better agreement between BISON-simulated cladding profilometry and PIE measurements for the peak caused by FCMI. This work shows that metallic fuel models used to accurately represent fuel performance for smaller EBR-II pins may be used for full-length metallic fuel, such as FFTF MFF assemblies and the Versatile Test Reactor (VTR). As new material models and PIE measurements become available, FFTF MFF assessment cases will be reassessed to further BISON model development.

36 MATERIALS SCIENCE↗

Qualification and Quantification of Porosity at the Top of the Fuel Pins in Metallic Fuels Using Image Processing

Approximately 130,000 metal fuel pins were irradiated in the Experimental Breeder Reactor II (EBR-II) during its 30 years of operation to develop and characterize existing and prospective fuels. For many of the metal fuel irradiation experiments, neutron radiography imaging was performed to characterize fuel behavior, such as fuel axial expansion. While several fuel expansion results obtained from neutron radiography imaging have been published, the analysis of neutron radiography for the purpose of describing statistical properties of porous matter formed on top of the fuel pins, also referred to as fluff in previous publications, is significantly less represented in the literature with just a single paper so far. This study aims to validate and augment results reported in previous publications using automated image processing. The paper describes the statistical properties of the porous matter in terms of nine parameters derived from radiography images and correlates those parameters with such fuel properties as composition, expansion, temperature, and burnup. The reported results are based on 1097 fuel pins of eight different fuel compositions. For three major fuel types, U-10Zr, U-8Pu-10Zr, and U-19Pu-10Zr, a clear negative correlation is found between the Pu content and five parameters describing the amount of porous matter generated. The parameters describing granularity properties, however, showed either negative correlation or nonlinear dependency from fuel composition. The parameters describing the amount showed a positive correlation with fuel axial expansion, while granularity parameters showed a negative correlation with axial expansion. The dependency on cladding temperature was found to be weak. A positive correlation is demonstrated for volume parameters and fuel burnup. In general, reported results confirm and validate findings published in previous studies using a much larger number of pins and automated processing techniques, which easily lend themselves to reproducibility, thus avoiding subjective bias.

36 MATERIALS SCIENCE↗

The actuated latch pin and its development

An actuated latch pin developed to meet the need for a reusable locking device is described. The unit can function as a pin puller or as a pin pusher latch. Initial prototype testing demonstrated the feasibility of the device with the unit being driven from a 28 V dc supply and using 15 W to drive a 12 mm diameter pin through a stroke of 10 mm with a side load of 100 N in 120 ms. High wear rates with a MOS2 lubrication on the ballscrew and angular contact bearings have necessitated the reduction in the duty cycle from 1000 cycles in air and vacuum to 100 in air and 1000 in vacuum.

Lawlor, P. J.↗

Locking Pull Pin

Proposed self-locking pull pin not accidentally released by shock or vibration but intentionally released by pull on lanyard. Any rotational movement of main pin traps secondary pin: prevents further rotation and disengagement of main pin.

Killgrove, T. O.↗

The stress distribution in pin-loaded orthotropic plates

The performance of mechanically fastened composite joints was studied. Specially, a single-bolt connector was modeled as a pin-loaded, infinite plate. The model that was developed used two dimensional, complex variable, elasticity techniques combined with a boundary collocation procedure to produce solutions for the problem. Through iteration, the boundary conditions were satisfied and the stresses in the plate were calculated. Several graphite epoxy laminates were studied. In addition, parameters such as the pin modulus, coefficient of friction, and pin-plate clearance were varied. Conclusions drawn from this study indicate: (1) the material properties (i.e., laminate configuration) of the plate alter the stress state and, for highly orthotropic materials, the contact stress deviates greatly from the cosinusoidal distribution often assumed; (2) friction plays a major role in the distribution of stresses in the plate; (3) reversing the load direction also greatly effects the stress distribution in the plate; (4) clearance (or interference) fits change the contact angle and thus the location of the peak hoop stress; and (5) a rigid pin appears to be a good assumption for typical material systems.

Klang, E. C.↗

A fiber-optic technique for the measurement of contact angle in a clearance-fit pin-loaded hole

A fiber-optic technique for measuring contact angle during pin loading of a specimen is proposed. The experimental design and procedures for loading a 49.8-mm-diameter instrumented pin into an quasi-isotropic graphite-epoxy specimen are described. The optical fiber was located just above the surface of the pin outer diameter in order to obtain accurate pin-hole contact-angle measurements at increasing load levels. The movement of the optical fiber through the no-contact, contact, and no-contact regions is discussed; the photodiode output decreased monotonically as the fiber moved from the no-contact to the contact region and then decreased monotonically as the fiber moved from the contact region to the no-contact region. Variations in the contact angle measurements are examined as function of applied load level. The measurements are compared to contact angle values obtained using a finite element analysis and an electrical technique; it is determined that the data correlate well.

Prabhakaran, R.↗

Comparative study of flux pinning flux creep and critical currents between YBaCuO crystals with and without Y2BaCuO5 inclusions

In the Y-Ba-Cu-O system YBa2Cu3Ox phase is produced by the following peritectic reaction: Y2BaCuO5 + liquid yields 2YBa2Cu3Ox. Through the control of processing conditions and starting compositions it becomes possible to fabricate large crystals containing fine Y2BaCuO5(211) inclusions. Such crystals exhibit Jc values exceeding 10000 A/sq cm at 77 K and 1T. Recently, researchers developed a novel process which can control the volume fraction of 211 inclusions. Elimination of 211 inclusions is also possible. In this study, researchers prepared YBaCuO crystals with and without 211 inclusions using the novel process and compared flux pinning, flux creep and critical currents. Magnetic field dependence of Jc for YBaCuO crystals with and without 211 inclusions is shown. It is clear that fine 211 inclusions can contribute to flux pinning. It was also found that flux creep rate could be reduced by increasing flux pinning force. Critical current density estimates based on the conventional flux pinning theory were in good agreement with experimental results.

Murakami, Masato↗

Comparative study of flux pinning, creep and critical currents between YBaCuO crystals with and without Y2BaCuO5 inclusions

In the Y-Ba-Cu-O system, YBa2Cu3O(x) phase is produced by the following peritectic reaction: Y2BaCuO5 + liquid yields 2YBa2Cu3O(x). Through the control of processing conditions and starting compositions, it becomes possible to fabricate large crystals containing fine Y2BaCuO5(211) inclusions. Such crystals exhibit Jc values exceeding 10000 A/sq cm at 77 K and 1T. Recently, researchers developed a novel process which can control the volume fraction of 211 inclusions. Elimination of 211 inclusions is also possible. In this study, researchers prepared YBaCuO crystals with and without 211 inclusions using the novel process, and compared flux pinning, flux creep and critical currents. Magnetic field dependence of Jc for YBaCuO crystals with and with 211 inclusions is shown. It is clear that fine 211 inclusions can contribute to flux pinning. It was also found that flux creep rate could be reduced by increasing flux pinning force. Critical current density estimates based on the conventional flux pinning theory were in good agreement with experimental results.

Murakami, Masato↗

Thermal analysis of the FSP-1 fuel pin irradiation test

Thermal analysis of a pin from the FSP-1 fuels irradiation test has been completed. The purpose of the analysis was to provide predictions of fuel pin temperatures, determine the flow regime within the lithium annulus of the test assembly, and provide a standardized model for a consistent basis of comparison between pins within the test assembly. The calculations have predicted that the pin is operating at slightly above the test design temperatures and that the flow regime within the lithium annulus is a laminar buoyancy driven flow.

Lyon, William F., III↗

The Plastic Flow Field in the Vicinity of the Pin-Tool During Friction Stir Welding

The plastic flow field in the vicinity of the pin-tool during Friction Stir Welding (FSW) needs to be understood if a theoretical understanding of the process is to be attained. The structure of welds does not exhibit the flow field itself, but consists in a residue of displacements left by the plastic flow field. The residue requires analysis to extract from it the instantaneous flow field around the pin-tool. A simplified merry-go-round model makes sense of some tracer experiments reported in the literature. A quantitative comparison is made of the displacements of copper wire markers with displacements computed from a hypothetical plastic flow field. The hypothetical plastic flow field consists in a circular rotation field about a translating pin tool with angular velocity varying with radius from the pin centerline. A sharply localized rotational field comprising slip on a surface around the tool agreed better with observations than a distributed slip field occupying a substantial volume around the tool. Both the tracer and the wire displacements support the "rotating plug" model, originally invoked or thermal reasons, of the FSW process.

Bernstein, E. L.↗

Flow in the Proximity of the Pin-Tool in Friction Stir Welding and Its Relation to Weld Homogeneity

In the Friction Stir Welding (FSW) process a rotating pin inserted into a seam literally stirs the metal from each side of the seam together. It is proposed that the flow in the vicinity of the pin-tool comprises a primary rapid shear over a cylindrical envelope covering the pin-tool and a relatively slow secondary flow taking the form of a ring vortex about the tool circumference. This model is consistent with a plastic characterization of metal flow, where discontinuities in shear flow are allowed but not viscous effects. It is consistent with experiments employing several different kinds of tracer: atomic markers, shot, and wire. If a rotating disc with angular velocity w is superposed on a translating continuum with linear velocity omega, the trajectories of tracer points become circular arcs centered upon a point displaced laterally a distance v/omega from the center of rotation of the disc in the direction of the advancing side of the disc. In the present model a stream of metal approaching the tool (taken as the coordinate system of observation) is sheared at the slip surface, rapidly rotated around the tool, sheared again on the opposite side of the tool, and deposited in the wake of the tool. Local shearing rates are high, comparable to metal cutting in this model. The flow patterns in the vicinity of the pin-tool determine the level of homogenization and dispersal of contaminants that occurs in the FSW process. The approaching metal streams enfold one another as they are rotated around the tool. Neglecting mixing they return to the same lateral position in the wake of the tool preserving lateral tracer positions as if the metal had flowed past the tool like an extrusion instead of being rotated around it. (The seam is, however, obliterated.) The metal stream of thickness approximately that of the tool diameter D is wiped past the tool at elevated temperatures drawn out to a thickness of v/2(omega) in the wiping zone. Mixing distances in the wiping zone are multiplied in the unfolded metal. Inhomogeneities on a smaller scale than the mixing length are obliterated, but structure on a larger scale may be transmitted to the wake of a FSW weld.

Nunes, Arthur C., Jr.↗

Modeling of Unit-Cells With Z-Pins Using FLASH: Pre-Processing and Post Processing

Although the toughening properties of stitches, z-pins and similar structures have been studied extensively, investigations on the effect of z-pins on the in-plane properties of laminates are limited. A brief summary on the effect of z-pins on the in-plane tensile and compressive properties of composite laminates is presented together with a concise introduction into the finite element code FLASH. The remainder of the report illustrates the modeling aspect of unit cells with z-pins in FLASH and focuses on input and output data as well as post-processing of results.

Krueger, Ronald↗

Gratings and Random Reflectors for Near-Infrared PIN Diodes

Crossed diffraction gratings and random reflectors have been proposed as means to increase the quantum efficiencies of InGaAs/InP positive/intrinsic/ negative (PIN) diodes designed to operate as near-infrared photodetectors. The proposal is meant especially to apply to focal-plane imaging arrays of such photodetectors to be used for near-infrared imaging. A further increase in quantum efficiency near the short-wavelength limit of the near-infrared spectrum of such a photodetector array could be effected by removing the InP substrate of the array. The use of crossed diffraction gratings and random reflectors as optical devices for increasing the quantum efficiencies of quantum-well infrared photodetectors (QWIPs) was discussed in several prior NASA Tech Briefs articles. While the optical effects of crossed gratings and random reflectors as applied to PIN photodiodes would be similar to those of crossed gratings and random reflectors as applied to QWIPs, the physical mechanisms by which these optical effects would enhance efficiency differ between the PIN-photodiode and QWIP cases: In a QWIP, the multiple-quantum-well layers are typically oriented parallel to the focal plane and therefore perpendicular or nearly perpendicular to the direction of incidence of infrared light. By virtue of the applicable quantum selection rules, light polarized parallel to the focal plane (as normally incident light is) cannot excite charge carriers and, hence, cannot be detected. A pair of crossed gratings or a random reflector scatters normally or nearly normally incident light so that a significant portion of it attains a component of polarization normal to the focal plane and, hence, can excite charge carriers. A pair of crossed gratings or a random reflector on a PIN photodiode would also scatter light into directions away from the perpendicular to the focal plane. However, in this case, the reason for redirecting light away from the perpendicular is to increase the length of the optical path through the detector to increase the probability of absorption of photons and thereby increase the resulting excitation of charge carriers. A pair of crossed gratings or a random reflector according to the proposal would be fabricated as an integral part of photodetector structure on the face opposite the focal plane (see figure). In the presence of crossed gratings, light would make four passes through the device before departing. In the presence of a random reflector, a significant portion of the light would make more than four passes: After each bounce, light would be scattered at a different random angle, and would have a chance to escape only when it was reflected, relative to the normal, at an angle less than the critical angle for total internal reflection. Given the indices of refraction of the photodiode materials, this angle would be about 17 . This amounts to a very narrow cone for escape of trapped light.

Gunapala, Sarath↗

Design and Use of a Penetrating Deposition Nozzle for Z-Pinning Additive Manufacturing

Fused Filament Fabrication (FFF) involves depositing material layer-by-layer to create athree-dimensional object. This method often demonstrates high mechanical anisotropy in theprinted structure, leading to a drop in the material strength of the part when comparing structuresalong the deposition plane (X/Y-Axis) versus across layers in the build direction (Z-Axis). Initialefforts to improve anisotropy led to the development of the Z-Pinning process, where continuouspins are deposited across layers in the Z-Axis. Z-pinning has demonstrated significant gains intoughness and inter-layer strength, particularly in fiber-reinforced materials. However, thisprocess can also create flaws in the structure that increase in severity and frequency as the pinsgrow in length and diameter. To mitigate this, a penetrating nozzle has been developed thatextends a fine-tipped extrusion nozzle deep into the pin cavity and simultaneously extrudesmaterial as it retracts. This study investigates the printability of the penetrating nozzle for simplegeometries and evaluates the resulting Z-pinning mesostructure. As a result of this study, theprototype penetrating nozzle design was analyzed and built. Through a pressure driven flowanalysis it was determined that the penetrating nozzle extruder can not only flow extrudefilament. After a transient thermal simulation it was found that after a pause of 15 secondsresume printing with no drop in heat at nozzle exit.

Bales, Brenin↗

Large enhancement of the in-field critical current density of YBCO coated conductors due to composite pinning landscape

YBa 2 Cu 3 O 7 -based coated conductors (CCs) achieve the highest critical current densities (J c ) of any known superconductor and are a key technology for applications such as rotatory machines, high-field magnets and power transmission. Incorporation of nano-sized non-superconducting second phases as additional vortex pinning centers has been considered the most amenable route to further enhance J c at an industrial scale, and has been successfully used in commercial CCs. The resulting pinning landscape is quite complex, with both synergistic and competing interactions among the various types of defects. Particle irradiation, on the other hand, allows for a controlled post-processing incorporation of a well-defined defect morphology. We have previously shown that irradiation with protons and other light ions can further enhance the in-field J c in commercial state-of-the-art CCs. Here we develop a combined irradiation process that increases J c above values previously achieved by irradiating with only one species. Our new approach involves sequentially irradiating with 250 MeV Au ions and 4 MeV protons. For example, at T ~ 27 K (liquid neon) and μ 0 H ~ 4 T, a region of interest for rotatory machines applications, we obtain J c ~ 5 MA cm -2 , which is about 40% higher than the values produced by the individual irradiations. Finally, we conclude that this is due to the synergistic pinning effects of the introduced splayed, non-uniform columnar defects and small clusters.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Understanding and control of Zener pinning via phase field and ensemble learning

Zener pinning refers to the dispersion of fine particles which influences grain size distribution via movement of grain boundaries in a polycrystalline material. Grain size distribution in polycrystals has a significant impact on their properties including physical, chemical, mechanical, and optical to name a few. We explore the use of Phase-field modeling and machine-learning techniques to understand and improve the control of grain size distribution via Zener pinning in polycrystalline materials. We develop a machine learning model that determines the relative importance of various parameters to exercise microstructure control via Zener pinning. Our workflow combines high-throughput phase-field simulations and machine learning to address the computational bottlenecks associated with large-scale simulations as well as identify features necessary for microstructure control in polycrystals. A random forest (RF) regression model was developed to predict grain sizes based on five Phase-field model parameters, achieving an average prediction error of 0.72 nm for the training data and 1.44 nm for the test data. The importance of the input parameters is analyzed using the SHapley Additive exPlanations (SHAP) approach which reveals that diffusivity, volume fraction, and particle diameter are the most important parameters in determining the final grain size. These findings will allow us to select the best second-phase particles, optimize grain size distributions and thus design microstructures with the desired properties. The developed method is a highly versatile and generalizable approach that can be used to assess the combined effects of individual features in the presence of multiple variables.

36 MATERIALS SCIENCE↗