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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

RIA simulation tests using driver tube for ATF cladding

Pellet-cladding mechanical interaction (PCMI) is a potential failure mechanism for accident-tolerant fuel (ATF) cladding candidates during a reactivity-initiated accident (RIA). This report summarizes Fiscal Year (FY) 2017 research activities that were undertaken to evaluate the PCMI-like hoop-strain-driven mechanical response of ATF cladding candidates. To achieve various RIA-like conditions, a modified-burst test (MBT) device was developed to produce different mechanical pulses. The calibration of the MBT instrument was accomplished by performing mechanical tests on unirradiated Generation-I iron-chromium-aluminum (FeCrAl) alloy samples. Shakedown tests were also conducted in both FY 2016 and FY 2017 using unirradiated hydrided ZIRLO™ tube samples. This milestone report focuses on testing of ATF materials, but the benchmark tests with hydrided ZIRLO™ tube samples are documented in a recent journal article.a For the calibration and benchmark tests, the hoop strain was monitored using strain gauges attached to the sample surface in the hoop direction. A novel digital image correlation (DIC) system composed of a single high-speed camera and an array of six mirrors was developed for the MBT instrument to better resolve the failure behavior of samples and to provide useful data for validation of high-fidelity modeling and simulation tools. The DIC system enable a 360° view of a sample’s outer surface. This feature was added to the instrument to determine the precise failure location on a sample’s surface for strain predictions. The DIC system was tested on several silicon carbide fiber/silicon carbide matrix (SiC/SiC) composite tube samples at various pressurization rates of the driver tube (which correspond to the strain rates for the samples). The hoop strains for various loading conditions were determined for the SiC/SiC composite tube samples. Future work is planned to enhance understanding of the failure behavior of the ATF cladding candidates of age-hardened FeCrAl alloys and SiC/SiC composites in detail during RIA conditions informed by the computational studies performed under the US Department of Energy Office of Nuclear Energy Advanced Fuels Campaign. The testing instrument and the new DIC system will be further developed to reach different stress-state conditions and to perform tests at elevated temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Validation of Material Models For Automotive Carbon Fiber Composite Structures Via Physical And Crash Testing (VMM Composites Project)

As automotive fuel economy requirements increase, the push for reducing overall vehicle weight will likely include the consideration of materials that have not previously been part of mainstream vehicle design and manufacturing, including carbon fiber composites. Vehicle manufacturers currently rely on computer-aided engineering (CAE) methods as part of the design and development process, so going forward, the ability to accurately and predictably model carbon fiber composites will be necessary. If composites are to be used for structural components, this need applies to both, crash and quasi-static modeling. This final report covers the results of a five-year, $6.89M, 50% cost-shared research project between Department of Energy (DOE) and the US Advanced Materials Partnership (USAMP) under Cooperative Agreement DE-EE-0005661 known as “Validation of Material Models for Automotive Carbon Fiber Composite Structures Via Physical and Crash Testing (VMM).” The objective of the VMM Composites Project was to validate and assess the ability of physics-based material models to predict crash performance of automotive primary load-carrying carbon fiber composite structures. Simulation material models that were evaluated included micro-mechanics based meso-scale models developed by the University of Michigan (UM) and micro-plane models by Northwestern University (NWU) under previous collaborations with the DOE and Automotive Composites Consortium/USAMP, as well as five commercial crash codes: LS-DYNA, RADIOSS, VPS/PAM-CRASH, Abaqus, and GENOA-MCQ. CAE predictions obtained from seven organizations were compared with experimental results from quasi-static testing and dynamic crash testing of a thermoset carbon fiber composite front-bumper and crush-can (FBCC) system gathered under multiple loading conditions. This FBCC design was developed to demonstrate progressive crush, virtual simulation, tooling, fabrication, assembly, non-destructive evaluation and crash testing advances in order to assess the correlation of the predicted results to the physical tests. The FBCC was developed to meet a goal of 30-35% mass reduction while aiming for equivalent energy absorption as a steel component for which baseline experimental results were obtained from testing in the same crash modes. The project also evaluated crash performance of thermoplastic composite structures fabricated from commercial prepreg materials and low cost carbon fiber sourced from Oak Ridge National Laboratory. The VMM Project determined that no set of predictions from a CAE supplier were found to be universally accurate among all the six crash modes evaluated. In general, crash modes that were most dependent on the properties of the prepreg were more accurate than those that were dependent on the behavior of the joints. The project found that current CAE modeling methods or best practices for carbon fiber composites have not achieved standardization, and accuracy of CAE is highly reliant on the experience of its users. Coupon tests alone are not sufficient to develop an accurate material model, but it is necessary to bridge the gap between the coupon data and performance of the actual structure with a series of subcomponent level tests. Much of the unreliability of the predictions can be attributed to shortcomings in our ability to mathematically link the effects of manufacturing and material variability into the material models. This is a subject of ongoing research in the industry. The final report is organized by key technical tasks to describe how the validation project developed, modeled and compared crash data obtained on the composite FBCC to the multiple sets of CAE predictions. Highlights of the report include a discussion of the quantitative comparison between predictions and experimental data, as well as an in-depth discussion of remaining technological gaps that exist in the industry, which are intended to spur innovations and improvements in CAE technology.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Open stack thermal battery tests

We present selected results from a series of Open Stack thermal battery tests performed in FY14 and FY15 and discuss our findings. These tests were meant to provide validation data for the comprehensive thermal battery simulation tools currently under development in Sierra/Aria under known conditions compared with as-manufactured batteries. We are able to satisfy this original objective in the present study for some test conditions. Measurements from each test include: nominal stack pressure (axial stress) vs. time in the cold state and during battery ignition, battery voltage vs. time against a prescribed current draw with periodic pulses, and images transverse to the battery axis from which cell displacements are computed. Six battery configurations were evaluated: 3, 5, and 10 cell stacks sandwiched between 4 layers of the materials used for axial thermal insulation, either Fiberfrax Board or MinK. In addition to the results from 3, 5, and 10 cell stacks with either in-line Fiberfrax Board or MinK insulation, a series of cell-free “control” tests were performed that show the inherent settling and stress relaxation based on the interaction between the insulation and heat pellets alone.

25 ENERGY STORAGE↗
DOE OSTI2017

ICFA Beam Dynamics Newsletter

Electron beam ion sources technology made significant progress since 1968 when this method of producing highly charged ions in a potential trap within electron beam was proposed by E. Donets. Better understanding of physical processes in EBIS, technological advances and better simulation tools determined significant progress in key EBIS parameters: electron beam current and current density, ion trap capacity, attainable charge states. Greatly increased the scope of EBIS and EBIT applications. An attempt is made to compile some of EBIS engineering problems and solutions and to demonstrate a present stage of understanding the processes and approaches to build a better EBIS.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

Methods to Measure, Predict and Relate Friction, Wear and Fuel Economy

High-fidelity measurements of the coefficient of friction and the parasitic friction power of the power cylinder components have been made for the Isuzu 5.2L 4H on-highway engine. In particular, measurements of the asperity friction coefficient were made with test coupons using Argonne National Lab’s (ANL) reciprocating test rig for the ring-on-liner and skirt-on-liner component pairs. These measurements correlated well with independent measurements made by Electro-Mechanical Associates (EMA). In addition, surface roughness measurements of the Isuzu components were made using white light interferometer (WLI). The asperity friction and surface characterization are key inputs to advanced CAE simulation tools such as RINGPAK and PISDYN which are used to predict the friction power and wear rates of power cylinder components. Finally, motored friction tests were successfully performed to quantify the friction mean effective pressure (FMEP) of the power cylinder components for various oils (High viscosity 15W40, low viscosity 5W20 with friction modifier (FM) and specially blended oil containing consisting of PAO/ZDDP/MoDTC) at 25, 50, and 110°C.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

NEAMS Workbench 1.0 Beta

The mission of the US Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) Program is to develop, apply, deploy, and support state-of-the-art predictive modeling and simulation tools for the design and analysis of current and future nuclear energy systems. This is accomplished using computing architectures that range from laptops to leadership-class facilities. The NEAMS Workbench is a new initiative that will facilitate the transition from conventional tools to high-fidelity tools by providing a common user interface for model creation, review, execution, output review, and visualization for integrated codes. The Workbench can use common user input, including engineering scale specifications that are expanded into application-specific input requirements through the use of customizable templates. The templating process enables multi-fidelity analysis of a system from a common set of input data. Additionally, the common user input processor can provide an enhanced alternative application input that provides additional conveniences over the native input, especially for legacy codes. Expansion of the integrated codes and application templates available in the Workbench will broaden the NEAMS user community and will facilitate system analysis and design. Current and planned capabilities of the NEAMS Workbench are detailed here.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

A Complex Systems Approach to More Resilient Multi-Layered Security Systems

In July 2012, protestors cut through security fences and gained access to the Y-12 National Security Complex. This was believed to be a highly reliable, multi-layered security system. This report documents the results of a Laboratory Directed Research and Development (LDRD) project that created a consistent, robust mathematical framework using complex systems analysis algorithms and techniques to better understand the emergent behavior, vulnerabilities and resiliency of multi-layered security systems subject to budget constraints and competing security priorities. Because there are several dimensions to security system performance and a range of attacks that might occur, the framework is multi-objective for a performance frontier to be estimated. This research explicitly uses probability of intruder interruption given detection (P I ) as the primary resilience metric. We demonstrate the utility of this framework with both notional as well as real-world examples of Physical Protection Systems (PPSs) and validate using a well-established force-on-force simulation tool, Umbra.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Status of the SAS4A/SASSYS-1 Safety Analysis Code

SAS4A/SASSYS-1 is a simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced reactors. This report summarizes the current status of SAS4A/SASSYS-1, including the implementation of software quality assurance procedures for configuration management, new licenses, current users, and a gap assessment of the test suite. The existing copyright has been extended for an additional five years, which was essential so that Argonne can continue developing, distributing, and supporting the software for both domestic use and international collaborations. SAS4A/SASSYS-1 Version 5.2 was completed in March 2017 and released to users in May. The importance of SAS4A/SASSYS-1 maintenance reflects its relevance to a number of U.S. Department of Energy programs as well as domestic and international collaborations. External collaborations have also produced improvements in the SAS4A/SASSYS-1 code, and these are noted in this report. SAS4A/SASSYS-1 has a growing user base that continues to strengthen the promotion of advanced non-LWR reactor concepts. Additional users will help solidify DOE’s leadership role in fast reactor safety both domestically and in international collaborations.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Incorporation of Spatial Stochastic Variability into Paracousti-UQ

Waves propagating through natural materials such as ocean water encounter spatial variations in material properties that cannot easily be predicted or known in advance. Deterministic wave simulation algorithms must assume that all properties throughout the model space are precisely known. However, a stochastic wave simulation tool can parameterize the material as a stochastic medium with a certain probability distribution and correlation length. This report documents the addition of spatial stochastic variability into Paracousti-UQ, Sandia Geophysics Department's 3-D full waveform acoustic algorithm within stochastic media. The ability of the code to replicate Monte Carlo solutions in 1-D spatially variable media is also evaluated.

58 GEOSCIENCES↗
DOE OSTI2018

Status of SAS4A/SASSYS Code Developments (FY2018)

SAS4A/SASSYS is a simulation tool used to perform deterministic analysis of anticipated events as well as design basis and beyond design basis accidents for advanced liquid-metal-cooled nuclear reactors. [1] With its origin as SAS1A in the late 1960s, the SAS series of codes has been under continuous use and development for nearly fifty years. It has been identified as a critical element of safety analysis capabilities for the U.S. Department of Energy, [2] and it will be used to perform the transient safety analysis required to support the authorization basis for the Versatile Test Reactor (VTR).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

CFD Study of Impact of Part-to-Part Variations on Spark-Ignition Engine Charge Formation

Spark-ignition engines are the backbone behind people transportation around the world. The efficiency of spark-ignition engines is limited in practice by variations between engine cycles and cylinders within an engine that result from the manufacturing processes/tolerances. These variations impact knock limits and dilution tolerance, which results in more conservative settings for design and calibration settings, such as compression ratio, valve timing, and exhaust gas recirculation rates. Engine variations also have a significant impact on emissions generation, which can have a secondary impact on efficiency. A deeper understanding of the relative importance of these variations and their interactions on the charge preparation process can guide future decisions on machining tolerances and control strategies. This project will develop simulation tools and methodology to include the effects of some key manufacturing tolerances and their impact on engine performance and emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Distributed Wireless Antenna Sensors for Boiler Condition Monitoring

Monitoring the operational conditions of coal-fired boilers is an important task that could bring tremendous benefits, including in-situ process control, real-time health assessment of structural components, improved heat transfer efficiency, reduced downtime, etc. Moreover, in-situ distributed sensing of the boiler conditions would provide large scale in-situ measurement data that will help us gain fundamental understandings of the combustion and heat transfer processes as well as enable the developments of new simulation tools, which could eventually lead to better design and more efficient operation of the boilers. The objectives of this research were to (a) develop wireless passive antenna sensors without electronics; (b) demonstrate multi-modality sensing using a signal antenna sensor; and (c) fabricate the antenna sensor from high-temperature materials. In this project, we have demonstrated that an antenna sensor or sensor array without any electronics can be wirelessly interrogated from a distance. In addition, a low-cost compact wireless sensor interrogator was developed for dynamic interrogation of the passive antenna sensor. We validated that a dual-frequency antenna sensor is capable of simultaneous strain and temperature measurements or temperature and ash accumulation measurements; all parameters are relevant to boiler condition monitoring. By measuring the temperature and ash accumulation height simultaneously, the dielectric constant of the ash as well as its temperature dependency can also be characterized. This capability could lead to potential applications of the antenna sensor for combustion process monitoring based on the ash composition. We also investigated different techniques of fabricating the antenna sensor using high-temperature materials such as alumina substrate and platinum paste and characterized the thermal response of the antenna sensor. A linear relationship between the antenna resonant frequency and the temperature change was validated.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Dark Energy Studies with LSST using the Photon Simulator (Final Report)

This grant funded the development and dissemination of the Photon Simulator (PhoSim) for the purpose of studying dark energy at high precision with the upcoming Large Synoptic Survey Telescope (LSST) astronomical survey. The work was in collaboration with the Dark Energy Science Collaboration (DESC). Several detailed physics improvements were made in the optics, atmosphere and sensor, a number of validation studies were performed, and a significant number of usability features were implemented. Future work in DESC will use PhoSim as the image simulation tool for data challenges used by the analysis groups.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2019

Development of Heat Pipe Reactor Modeling in SAM

System Analysis Module (SAM) is under development at Argonne National Laboratory as a modern system-level modeling and simulation tool for advanced non-light water reactor safety analyses. It utilizes the object-oriented application framework MOOSE to leverage the modern software environment and advanced numerical methods available in PETSc. The capabilities of SAM are being extended to enable the transient modeling, analysis, and design of various advanced nuclear reactor systems. This report presents the development of new capabilities for modeling the heat pipe type reactor systems. The need for power at remote locations away from a reliable electrical grid is an important niche for nuclear energy. Heat pipe-cooled fast-spectrum nuclear reactors are well suited for these applications. The key feature of the heat pipe reactors is the use of heat pipes for heat removal from the reactor core. The heat pipe makes use of the phase change of the working fluid and transports a large amount of heat from the evaporator to the condensation end with very small temperature drops. In contrast to the traditional nuclear reactor system that makes use of pumped loop for extracting the thermal power, the heat pipe reactors make use of hundreds of heat pipes for removing the thermal power (including the decay heat) passively. This could potentially significantly improve the reliability and safety of the reactor systems. The essential part in the analysis of a heat pipe type reactor is the modeling of heat transport inside the heat pipe. The capability of SAM is extended in this work to enable the modeling of the conventional heat pipe. Two alternative modeling options, 2D-RZ Heat conduction and 3D-1D coupling, are developed, which are both based on the assumption that the heat pipe vapor core can be modeled as a superconductor of extremely high thermal conductivity. Both modeling options are verified with a simplified thermal resistance model. The heat pipes are also coupled with the fuel region of a prototype micro reactor under both normal and off-normal conditions. It is confirmed that both modeling options can correctly model the heat transport in the heat-pipe reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Improving Fission Products at CARIBU: Near Field Detection (Q3/FY19 Quarterly Progress Report)

In the last quarter, Miguel Bencomo joined our group as a postdoc. Miguel got his PhD degree from Texas A&M University last December, where he was working on precision beta decay measurements, using techniques similar to the approach we use to measure branching ratios. We have been training him on how to use our analysis and simulation tools, as well as bringing him up to speed on the technical details of our experiment. The analysis and writing the manuscript for 95 Zr has been completed and are waiting for a feedback from Texas A&M collaborators. This process has been slightly delayed due to vacations and their obligations to other experiments at Texas A&M. We have begun working with Benjamin Schroeder (PhD student from Texas A&M), he is currently learning our analysis tools and looking at decay data of 95 Zr. Ben has just finalized his Master thesis and is very well positioned to start working with us, by first learning our analysis technique on 95 Zr proof-of-principle data, and next be responsible for analysis 156 Eu data that we plan to take later this year.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2018

Fabrication and Modeling of Laser Additive Manufactured Materials with Multi-Beam Adaptive Beam Shaping

The objective of this research was to fabricate laser additive manufactured samples using the multi-beam fiber laser array system developed by Optonicus, and to test the ability of existing simulation tools to help understand the influence of various beam configurations on the heat transfer and solidification conditions that control microstructure development during processing. Optonicus produced Inconel 718 samples with two different beam configurations that exhibited dramatically different microstructure characteristics. A simplified analytical model was used in conjunction with microstructure selection theory to relate the differences in beam configuration and process conditions to the changes in microstructure. The analytical model was verified against standard quasi-static solutions and a numerical Computational Fluid Dynamics CFD model and the influence of fluid mechanics on the melt pool geometry was evaluated.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Process Modeling for Additive Manufacturing

Additive Manufacturing (AM) provides a new avenue to design innovative materials and components that cannot be created using traditional machining operations. With current AM capabilities, complex designs (such as those required in weapon systems) can be readily manufactured with laser powder forming (or Laser-Engineered Net Shaping (LENSTM)) [1] that would be otherwise cost prohibitive or impossible to produce. However, before an AM product can be qualified for weapon applications, the characteristics of the metals produced by additive manufacturing processes need to be well understood. This work focuses on the development of computational simulation tools to model the metal additive manufacturing process. This work extends and integrates existing Sandia National Laboratories tools to accomplish the following: (i) be able to better predict residual stresses in AM product, (ii) extend high-fidelity material models to capture material evolution during the formation process, leading to prediction of end-state material properties, and (iii) provide a basis for engineering tools to propose improvements to additive manufacturing process variables, including those that minimize process variation. While this work in its current state is directly applicable to additive manufacturing processes, the tools developed may also help enable modeling welding processes such as gas tungsten arc (GTA), electron beam, and laser welding.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2019

NEAMS Workbench Status and Capabilities

The mission of the US Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program is to develop, apply, deploy, and support state-of-the-art predictive modeling and simulation tools for the design and analysis of current and future nuclear energy systems. This is accomplished by using computing architectures that range from laptops to leadership-class facilities. The NEAMS Workbench is a new initiative that will facilitate the transition from conventional tools to high fidelity tools by providing a common user interface for model creation, review, execution, output review, and visualization for integrated codes. The Workbench can use common user input, including engineering-scale specifications that are expanded into application-specific input requirements through the use of customizable templates. The templating process can enable multifidelity analysis of a system from a common set of input data. Additionally, the common user input processor can provide an enhanced alternative application input that provides additional conveniences over the native input, especially for legacy codes. Expansion of the integrated codes and application templates available in the Workbench will broaden the NEAMS user community and will facilitate system analysis and design. Current and planned capabilities of the NEAMS Workbench are detailed here.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗