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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 OSTI2023

Multi-scale fission product release model with comparison to AGR data

TRistructural ISOtropic (TRISO) particle fuel is central to several advanced, high-temperature reactor designs. Each particle consists of a fuel kernel encapsulated by three layers of carbon and ceramics that prevent the release of fission products and ensure physical integrity. Despite outstanding retention properties, fission product release has been observed from intact particles. To better understand and quantify fission product release from TRISO particles, a multiscale, mechanistic model of fission product transport is being developed by the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program. Previous work focused on silver (Ag) transport and improved Ag release predictions. The work described in this report builds on this experience to better understand cesium (Cs) transport in silicon carbide (SiC), the main barrier to the release of fission products. Atomistic simulations provide bulk and grain boundary (GB) Cs diffusivities in SiC, which are used by phase field simulations in the mesoscale code Marmot to determine the temperature, microstructure, and irradiation-dependent Cs diffusivity at the mesoscale in SiC. This approach attributes the different temperature regimes experimentally observed for Cs diffusivities in SiC to a transition from bulk-dominated diffusivity at high temperatures to a GB-dominated regime at low temperatures, providing new insight. The multiscale, mechanistic effective diffusivity is then implemented in the fuel performance code BISON and further validated by comparing Cs release predictions from Advanced Gas Reactor (AGR)-1 and AGR-2 post-irradiation measurements. The new model improves BISON’s predictability. This document also reports improvements made on Ag transport modeling by accounting for different GB types having different diffusivities. Moreover, this report details preliminary efforts to model palladium (Pd) attack of the SiC at the mesoscale using a phase field approach. Pd attack and its impact on accelerated Ag transport remains a misunderstood phenomenon, and we use the model to demonstrate that the formation of lamellae that has been observed in experiments can be explained by the reaction of Pd with SiC to form alternating layers of graphite and Pd 2 Si. This effort aims to improve our understanding of the reaction and eventually provide a model for BISON to account for Pd penetration and its effects on fission product release.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Solid breeder material crystal structure evolution due to Li burn up–Loss of crystal stability

Solid breeder materials for fusion power plants are subjected to extreme conditions of radiation damage, high temperature and designed component burn-up. Here, the loss of lattice stability of Li 2 TiO 3 due to Li burn-up was investigated using first principles-based approaches to aid evaluation of upper limit of component lifetime. The lattice stability is analyzed using calculated phonon dispersion in the Li 2 TiO 3 supercell, while Li burn-up is modeled by the introduction of Li-vacancies. It has been determined that the studied ceramic can be structurally stable up to ~40% of Li atoms burn-up. At 50% burn-up, the negative frequency branch in the phonon dispersion spectrum appears indicating the loss of lattice dynamical stability. Moreover, the structure obtained by introduction of unstable frozen phonons with minima energy amplitude also results in a phonon dispersion with negative branches in the structure obtained. Therefore, the system completely loses stability when approximately half of Li atoms are consumed.

36 MATERIALS SCIENCE↗
DOE OSTI2022

HTS Cable Conductor for Compact Fusion Tokamak Solenoids

Significant progress has been made recently in the US fusion community to develop a strategic plan to enable engineering design and construction of a fusion pilot plant (FPP). Princeton Plasma Physics Laboratory (PPPL) is working on developing high current density HTS conductors for next fusion experiments. Partnering with the US industry, we are evaluating feasibility and affordability of Conductor on Round Core (CORC ® ) developed by Advanced Conductor Technologies (ACT) for the next compact fusion tokamak facility. High current density achieved by a CORC ® cable based on a four-layer model coil recently tested at National High Magnetic Field Laboratory (NHMFL) motivated its consideration for low cost, reduced size fusion magnet application. This is of interest to PPPL because of its scalability to tokamak central solenoid (CS) coils in terms of required flux swings for plasma startup operations. Furthermore, partnering with ACT, we designed and built a two-layer model coil solenoid directly wound with CORC to demonstrate its applicability for compact solenoids such as that used in the national spherical torus experiment (NSTX), NSTX-upgrade (NSTX-U) and the US sustained high-power density test facility (SHPD). The ~160 mm diameter solenoid wound by a two-layer CORC is being tested in early 2022 under electromagnetic cyclic loading at NHMFL in a unique 160 mm bore, 14 T background field magnet facility.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Metal (Cu,Al)/CNT Composite Wires for Energy Efficient Motors

This report summarizes the main results of research project on Metal/CNT nanocomposites conducted at University of Central Florida (UCF). It should be noted that the project was budgeted for three years, but the budget period 3 was unfortunately not funded and conducted in COVID19 pandemic years due to many reasons. The demonstration plan on the small motors was also removed according to the discussion with the DOE program manager. All research activities were focused on the (Cu,Al)/CNT material development and wire extrusion. Existing methods to fabricate Metal/CNTs were usually suffering from agglomeration of CNTs due to their density and stiffness differences. A new method is studied by the UCF research team, where CNTs are surface treated firstly, then coated with pure metals (i.e., Al, Cu, and Nickle). The metal encapsulation on CNT is expected to significantly improve the interfacial bonding between CNTs and the intimated metal matrices. The coated CNT powders were used to make sample materials through sintering, then a customized wire extrusion process was employed to fabricate wires. Measurement of material property improvements in mechanical strength, thermal conductivity, and electrical conductivity were conducted on both cylinder samples and extruded wires. In addition to the sintering process, casting on metal coated CNT powder was also investigated. The best results we achieved are summarized as follows. (1) The measured thermal conductivity of Al/CNT composite made with Ni-encapsulated CNTs and pure Al powders is about 85% better than that of pure aluminum fabricated. The measured electrical conductivity of fabricated Al/CNT is about 14-20% better than that of pure aluminum. (2) The measured electrical conductivity of Cu/CNT is about 14.5% better than that of pure copper fabricated. (3) The mechanical strengths of both Cu/CNT and Al/CNT (with about 1% wt. CNTs) are 70% better than pure metals although losing some material ductility. (4) Two-stage wire extrusion at high temperatures were designed and successfully conducted to fabricate wires of Metal/CNTs.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Comprehensive Evaluation of the Advanced Moderator Module (AMM)

The U.S. nuclear sector is now focusing on advancing and deploying microreactors that blend efficiency, compactness, and safety. For thermal neutron microreactors designed for high temperature operations, employing a metal hydride-based moderator presents a valuable opportunity to enhance neutron efficiency. Argonne National Laboratory (ANL) has pioneered an Advanced Moderator Module (AMM) featuring an innovative containment strategy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Enhanced Design of Radiation Tolerant High-Temperature Structural Health Monitoring Sensors

Acoustic emission sensors are vital in the nuclear industry for real-time structural health monitoring and early detection of material degradation. By capturing high-frequency stress waves emitted from defects like cracks, corrosion, or fatigue, acoustic emission sensors enable non-invasive monitoring of critical components such as reactor vessels, piping, and containment structures. This technology supports predictive maintenance, enhances safety, and ensures regulatory compliance by providing early warnings of potential failures. It is also instrumental in research, particularly in material testing reactors, where it is used to monitor the behavior of fuels and materials under irradiation, by allowing the detection of cracking or other acoustic signals in real time. This enables the evaluation of performance and accident behavior of advanced fuel concepts.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2024

Time-Dependent Failure Assessment of Ceramic Receivers

The outlet temperature targets for Gen 3 Concentrating Solar Power (CSP) systems pose a significant challenge to the structural reliability of high temperature metallic components, including those manufactured from nickel-based superalloys. Advanced ceramics present a potential solution due to their excellent high-temperature strength. However, accurate assessment of ceramic components requires an entirely different approach compared to metallic components. This paper describes the implementation of time-dependent reliability analysis of ceramic components in srlife – an open-source software package for estimating the life of high temperature CSP components. This new capability will allow high temperature CSP designers to make fair comparisons between competing metallic and ceramic designs and accurately assess the performance of different ceramic materials for CSP receivers and other components. The current version of the tool is available at https://github.com/Argonne-National-Laboratory/srlife.

Barua, Bipul (ORCID:0000000247184113)↗
DOE OSTI2023

FY23 status report on the development of new ASME Section III, Division 5 Class B rules

This report summarizes the work done in Fiscal Year 2023 on the development of the new American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section III, Division 5, Class B rules to address the gaps identified for high temperature reactor designs. The summary of the design-by-analysis strain limit evaluation and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. This approach captures the elastic follow-up generated due to interactions of components with adjacent components, supports, and other connections in the power plant. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules, and the experimental data obtained from a family of Simplified Model Test based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

AGC-2 Graphite Preirradiation Data Analysis Report

This report describes the specimen loading order and documents all preirradiation examination material property measurement data for graphite specimens contained within the Second Advanced Graphite Capsule (AGC 2) irradiation capsule. The AGC 2 capsule is the second in six planned irradiation capsules comprising the Advanced Graphite Creep (AGC) test series. The AGC test series is used to irradiate graphite specimens in order to garner quantitative data necessary for predicting the irradiation behavior and operating performance of new nuclear grade graphites. This testing will ascertain the in service behavior of the graphite for pebble bed and prismatic very high temperature reactor designs. Similar to the First Advanced Graphite Capsule (AGC 1) preirradiation examination report, material property tests were conducted on specimens from 18 nuclear grade graphite types. However, AGC 2 tested an increased number of specimens (i.e., 512) prior to loading them into the AGC 2 irradiation assembly. All AGC 2 specimen testing was conducted at Idaho National Laboratory from July 2009 to August 2010. This report also details the specimen loading methodology for graphite specimens inside the AGC 2 irradiation capsule. The AGC 2 capsule design requires “matched pair” creep specimens that have similar dose levels above and below the neutron flux profile mid plane. This provides similar specimens with and without an applied load. Analysis in this document utilizes the neutron flux profile calculated for the AGC 2 capsule design, the capsule dimensions, and the size (i.e., length) of the selected graphite specimens to create a stacking order that produces “matched pairs” of graphite specimens above and below the AGC 2 capsule elevation mid point, thus providing specimens with similar neutron dose levels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to fullscale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This CRADA project was the result of a project award under FOA-DOE-0001980. The overarching FOA project team consisted of researchers from Carpenter Technology Corporation (CTC), Solar Turbines Incorporated (Solar), Pennsylvania State University (PSU), University of California-Santa Barbara (UCSB), and Oak Ridge National Laboratory (ORNL). Evaluations were conducted on two high-γ’ superalloys that were designed by CTC and the UCSB. One alloy named GammaPrint-700 (GP-700) is a cobalt-base superalloy. The other alloy named GammaPrint-1100 (GP-1100) is a nickel-base (Ni-base) superalloy. PSU provided expertise and experimental testing of the thermal performance of AM micro-cooling architectures. ORNL provided expertise with the AM superalloy materials characterization and AM processing science. Solar provided turbine component design expertise. The focus of this CRADA report is to document the efforts between ORNL and CTC towards the development of superalloys designed for AM. The project goal was to use an AM processable high-temperature superalloy and design for Additive Manufacturing (DfAM) techniques to design an efficient turbine component (i.e. a turbine tip shoe) with enhanced cooling features that can only be fabricated through additive manufacturing (AM). The efficiencies of existing combined heat and power (CHP) engines are capped by both component design and materials limitations. However, AM of a tip shoe component from a γ’strengthened superalloy offers the design flexibility to increase the efficiency and power of an industrial gas turbine. This project brought about advancements in the DfAM tip shoe design space and in the area of high temperature superalloys processable through laser powder bed fusion (LPBF) AM. State of art computation design tools were utilized to optimize unique cooling features into a tip shoe component design. A two-prong materials development approach was taken to support development of the AM tip shoe geometry. The first approach centered on investigating the processability and the appropriate process science for the industry standard high-γ’ nickel-base (Ni-base) superalloy Mar-M247. This superalloy is typically cast and considered non-weldable by traditional welding standards. In the course of this work, the alloy was not deemed feasible for process scale-up due to significant cracking issues during printing. The second approach focused on the development and evaluation of a novel cobalt-base superalloy, GammaPrint™-700 (GP-700 and a Ni-base superalloy, GammaPrint™-1100 (GP-1100) designed to mitigate the significant AM processing issues with Mar-M247. The processability of these two alloys were investigated through electron beam melting (EBM) binder-jet AM (BJAM), and LPBF as a risk mitigation for manufacturability. To be considered a candidate material for down-selection to proceed to full-scale AM tip shoe engine testing trials, the high temperature creep rupture strength was required to achieve at a minimum, a Larsen Miller Parameter (LMP) increase of 10.9% over the baseline material LPBF AM Hastelloy X.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2022

A Structural Design Approach Tailored for the Rapid Preliminary Design of Microreactor Components

High-temperature microreactors can play a role in developing reliable, portable energy sources for off-grid remote locations, microgrid concepts, and industrial process heat. Portability and passive safety criteria tend to skew microreactor structural component designs toward complex geometries, high thermal stresses, and design bases with large numbers of startup/shutdown cycles. Current design rules, as typified by Section III of the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, are less than optimal for these conditions, particularly for preliminary component designs where developers need to rapidly consider a large number of potential component configurations. This paper presents a design method targeted toward rapid, efficient evaluation of preliminary component designs using modern finite element analysis. The new method retains key connections with the ASME Code rules and design data while streamlining the design approach. This paper presents the design method, several verification examples illustrating the similarities and differences between the new method and the current ASME rules, and the application of the new approach to the evaluation of a test article mimicking key features of a heat pipe–cooled microreactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Conceptual Design of High Field Central Solenoid for Fusion Nuclear Science Facility

Fusion Nuclear Science Facility (FNSF) is a critical fusion nuclear step in the US beyond ITER before proceeding to a larger and electricity producing fusion power plant. Although FNSF is a steady state machine to be operated at high duty cycle, a high field and high current density central solenoid magnet is needed for plasma startups. Due to space constraints in the FNSF in-board radial build, the magnetic field and coil current density required exceed conventional low temperature superconductor (LTS) performance limits and the design can only be achieved by high temperature superconductors (HTS). The design for the central solenoid, also called the ohmic heating (OH) magnet for FNSF shall meet the 100 Weber double flux swing requirement for plasma startups. Finally, the stresses at such a high field and high current density coil may require a bucked and wedged TF-OH design to accommodate space for coil winding support structures in in-board system radial build for high field FNSF operations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗