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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 OSTI2018

Final Report on CFD and Thermal-Mechanical Stress Analysis of PWR Surge Line under Transient Condition Thermal Stratification and an Evolutionary Cyclic Plasticity Based Transformative Fatigue Evaluation Approach without Using S~N Curve: Rev. 1

This report presents an evolutionary cyclic plasticity based transformative approach for fatigue evaluation of safety critical components. This approach is generic which can be used not only for the present generation light water reactor components (which is our focus) but also for advanced reactor components. The approach is based on the fundamental concept of time-evolution of progressive fatigue damage rather than the end-of-life data based conventional S~N curve approaches. Series of fatigue tests on 316 stainless steel uniaxial specimens were conducted under strain-controlled and stress-controlled cyclic loading in two different environment such as in-air at 300 °C and PWR coolant water condition at 300 °C. Material models are developed to capture the uniaxial test data and are subsequently programmed into commercially available ABAQUS code to transform the uniaxial material behavior to multiaxial loading domain. The developed evolutionary cyclic-plasticity approach is verified by both analytical and 3D-FE modeling of uniaxial fatigue test specimens. Results show that the developed material models can capture the time-dependence of material hardening and softening with great accuracy. In addition, results show that the material models not only can capture the material behavior under constant amplitude loading but also can capture the load-sequence effect under variable and random amplitude loading. The ANL developed approach is one of its kind, which shows first in the fatigue research community that fatigue evaluation of a component (in our case verified for laboratory scale fatigue test specimens with great accuracy) can be performed for its entire fatigue life, including the hardening and softening behavior, without using a conventional S~N curve based approach. Additionally results are presented related to fatigue evaluation of real reactor components such as of a pressurized water reactor (PWR) surge line (SL), under upset transient conditions. SLs of PWR experience complex thermal stratification due to the mixing of differential temperature flow from hot leg and pressurizer. A detailed parametric study of thermal stratification in SL is performed through both standalone computational fluid dynamics (CFD) analysis and fluid-structure-interaction based coupled CFD and heat transfer analysis. Results show that the mass flow rate in SL substantially affects the extent of its thermal stratification. The resulting thermal boundaries conditioned are used as inputs for thermal-mechanical stress analysis and component level fatigue evaluation. Fatigue evaluation of SL pipe under example loading conditions was performed using the above-mentioned evolutionary-plasticity based approach and ASME code (for in-air life) and NUREG-6909 (for PWR environment life) based approaches. Results show that the evolutionary plasticity based approach estimate substantially different life compared to the conventional ASME based approach. To show the entirety of the proposed evolutionary fatigue-modeling framework, this report includes the results presented in semi-annual March report (ANL/LWRS-17/01). Sections 2-5 of March report are directly included as Sections 2-5 in this report, without any significant changes. However, Sections 6-9 of this report present the work performed during March-September of 2017. Whereas, Sections 1 and 10 present the organization of this report and the summary and future work, respectively. This report (ANL/LWRS-17/03 Rev. 1) is a slightly revised version of the earlier published report (ANL/LWRS-17/03). In this revised version, some of the results and associated discussion have been corrected/updated.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Burning Plasma Science: Long Pulse-Materials and Fusion Nuclear Science (Final Project Report)

The series of International Conferences on Fusion Reactor Materials (ICFRM) has been established nearly forty years ago as the major international forum for exchanging and archiving a growing knowledge based on the development of materials for both near and long-term fusion energy systems. The critical role of materials science and engineering in overcoming the technological challenges to making fusion energy a practical reality has been an overarching theme of invited and contributed oral talks as well as the poster session presentations. ICFRM is the premier international forum connecting specialists in the area of development of materials for both near and longer-term fusion energy systems. A central theme is the sharing of new insights, cutting-edge research, and technology in materials science pertaining to the realization of fusion energy. The conference consists of daily overview plenary lectures, invited and contributed oral presentations, and a series of technical poster sessions. In addition to hosted satellite meetings, pre-conference technical tutorials, and stimulating discussions. The 19th International Conference on Fusion Reactor Materials (ICFRM-19) was held in La Jolla, California, U.S.A. during the period October 27 through November 1, 2019. We describe here the conference background, topics, structure, program, schedule and timeline, publications, venue, satellite meetings, short courses and seminars, and finally the budget and expenses.

36 MATERIALS SCIENCE↗
NASA NTRS1975

Large furlable antenna study

The parametric study of the performance of large furlable antennas is described and the availability of various size antennas is discussed. Three types of unfurlable reflector designs are considered: the wrapped rib, the polyconic, and the maypole. On the basis of these approaches, a space shuttle launch capability, and state-of-the-art materials, it is possible to design unfurlable reflectors as large as 130 feet (40 meters) in diameter to operate at 10 GHz and 600 feet (183 meters) in diameter at 0.5 GHz. These figures can be increased if very low thermal coefficient of expansion materials can be developed over the next 2-5 years. It is recommended that a special effort be made to develop light weight materials that would provide nearly zero thermal coefficient of expansion and good thermal conductivity within the next 10 years. A conservative prediction of the kinds of unfurlable spacecraft antennas that will be available by 1985 with orbital performance predicted on the basis of test data and with developed manufacturing processes is summarized.

Campbell, G. K. C.↗
DOE OSTI2020

Terrestrial radiative cooling: Using the cold universe as a renewable and sustainable energy source

Photonic materials designed at wavelength scales have enabled a range of emerging energy technologies, from solid-state lighting to efficient photovoltaics that have transformed global energy landscapes. Daytime passive radiative cooling materials shed heat from the ground to the cold universe by taking advantage of the terrestrial thermal radiation that is as large as the renewable solar energy. Newly developed photonic materials permit subambient cooling under direct sunshine, and their applications are expanding rapidly enabled by scalable manufacturing. We review here the recent advancement of daytime subambient radiative cooling materials, which allow energy-efficient cooling and are paving the way toward technologies that harvest the coldness from the universe as a new renewable energy source.

Science & Technology - Other Topics↗
DOE OSTI2025

Understanding and Developing Dual-Wavelength Olefin Metathesis Polymerizations for the Rapid, Continuous Additive Manufacturing of High-Performance Thermosets

This report details the goals, approach, results, and future needs of a three-year Laboratory Directed Research and Development project funded by Sandia’s Materials Science Research Foundation. In this project, we established basic principles and mechanistic understanding of orthogonal or sequential chemistries for fabricating multi-material or robust materials. We developed numerous additive manufacturing, or 3D-printing, techniques including volumetric solid-state printing, dual-wavelength printing, and lithographic regulation of polymer crystallinity. We leveraged these new printing motifs to expand upon what is possible with manufacturing to give bespoke optical and mechanical performance. Moreover, we discovered new techniques for depolymerization enabling recovery of pristine carbon-fiber and high value electronics under moderate conditions.

36 MATERIALS SCIENCE↗
NASA NTRS2000

Advanced Hydrocarbon Fuel Development

As a part of a high energy density materials (HEDM) development, the hot fire tests for Quadricyclane, 1,7 Octadiyne, AFRL-1, Biclopropylidene, and CINCH (Dimethyl amino ethyl azide) have been conducted at NASA/MSFC. The first 4 materials for this task are provided from Air Force Research Laboratory at Edward Air Force Base and US Army provided CINCH. The performance of these fuels is compared with RP-1. The preliminary results of these tests are presented. The preliminary results of Quadricyclane tests indicate that the specific impulse and c-star efficiency for quadricyclane at the mixture ratio 1.94 are approximately 5 sec and 105 ft/sec better than the RP-1 at mixture ratio 1.9. The 1,7 Octadiyne test indicate that the specific impulse and c-star efficiency at the mixture ratio 2.1 are approximately -1 sec and 89 ft/sec differ than the RP-1 at mixture ratio 2.04. The Quadricyclane soot buildup at the combustor is a little more than RP-1, but detail study of soot formation is not considered at this time. There was no visual soot buildup for the 1,7 Octadiyne and AFRL-1.

Bai, S. Don↗
DOE OSTI2021

Graphitic Aza-Fused π-Conjugated Networks: Construction, Engineering, and Task-Specific Applications

2D π-conjugated networks linked by aza-fused units represent a pivotal category of graphitic materials with stacked nanosheet architectures. Extensive efforts have been directed at their fabrication and application since the discovery of covalent triazine frameworks (CTFs). Besides the triazine cores, tricycloquinazoline and hexaazatriphenylene linkages are further introduced to tailor the structures and properties. Diverse related materials have been developed rapidly, and a thorough outlook is necessitated to unveil the structure–property–application relationships across multiple subcategories, which is pivotal to guide the design and fabrication toward enhanced task-specific performance. Herein, the structure types and development of related materials including CTFs, covalent quinazoline networks, and hexaazatriphenylene networks, are introduced. Advanced synthetic strategies coupled with characterization techniques provide powerful tools to engineer the properties and tune the associated behaviors in corresponding applications. Case studies in the areas of gas adsorption, membrane-based separation, thermo-/electro-/photocatalysis, and energy storage are then addressed, focusing on the correlation between structure/property engineering and optimization of the corresponding performance, particularly the preferred features and strategies in each specific field. In the last section, the underlying challenges and opportunities in construction and application of this emerging and promising material category are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

An energetic link between order and strength in metals: A nanocrystalline strength limit in high-entropy alloys and intermetallic compounds

The metallurgy and materials communities have long understood and exploited fundamental links between chemical and structural ordering in metallic solids to tailor their mechanical properties. We extend these ideas to include prediction of the nanocrystalline strength limit in high-entropy alloys and intermetallic compounds, where a breakdown occurs in the classical Hall-Petch strengthening behavior. The highest reported strength achievable through alloying has rapidly climbed and given rise to new classifications of materials with extraordinary properties, with a notable case being nanocrystalline metals. High-entropy alloys (chemically disordered, concentrated solid solutions) and intermetallic compounds are two boundary cases of how tailored order can be used to manipulate mechanical behavior. Here, we show that the complex electronic-structure mechanisms governing the peak strength of alloys and pure metals can be reduced to a few physically meaningful parameters based on their atomic arrangements and used – with no fitting parameters – to predict the maximum strength of these materials. This includes a generalized energy-based accounting for the degree of structural and chemical ordering that allows for rapid and reasonably accurate prediction of peak strength (validated in the nanocrystalline limit) as a function of temperature. Predictions of maximum strength based on the activation energy (with all materials properties derived from DFT calculations or experiments) for a stress-driven transition to an amorphous state is shown to accurately describe the breakdown in Hall-Petch behavior at the smallest crystallite sizes for pure metals, intermetallic compounds, high-entropy alloys, and metallic glasses. Further, this activation energy is also shown to be directly proportional to interstitial electronic charge density, which is a good predictor of ductility, stiffness (moduli), and phase stability in high-entropy alloys and solid metals generally. The proposed framework suggests the possibility of coupling ordering and intrinsic strength to mechanisms like dislocation nucleation, hydrogen embrittlement, and transport properties, such as through correlations between the activation energies for amorphization with stacking-fault and grain boundary energies. It additionally opens the prospect for greatly accelerated structural materials design and development to address materials challenges limiting more sustainable and efficient use of energy.

36 MATERIALS SCIENCE↗
DOE OSTI2018

South Carolina Solar Development - Tracking the Effects of Act 236 (2014-2017)

Since 2014, the installed solar capacity in South Carolina (SC) has mushroomed from 5.5 megawatts to more than 354 megawatts today. Concurrently, the number of customer-sited, load-centered solar generation was expected to grow from less than 600 statewide to as many over 10,000 today. This growth was the direct result of a landmark state policy initiative, Act 236, passed by the SC General Assembly and signed into law by the Governor in June of 2014. Local policy makers in SC were ill-equipped to handle the onslaught of solar permitting and zoning requests expected by 2021. Similarly, the state’s building inspectors, first responders, and tax assessors know little about photovoltaic (PV) technology and best practices. Finally, SC’s workforce and workforce trainers were underprepared to benefit from the tremendous opportunity created by the passage of Act 236. Each of these deficits in knowledge of and preparedness for solar PV translated into higher “soft costs” of installed solar PV in SC. The Savannah River National Laboratory (SRNL), together with almost a dozen electricity stakeholders in the Southeast, has studied the ability of Act 236 to serve as replicable model for solar PV cost reduction. In 2015, this study began with a focus on the effects of Act 236 to offer a unique perspective and understanding of the actual impact of rapidly integrating solar energy into the electric grid. This study would analyze the impact of starting at a solar PV penetration of 0.1% and increasing to over 2%, while expanding access, developing regional specific training and educational materials, and developing datasets to support expanding solar markets. Through targeted tracking and analysis, the team developed a baseline of the current market, identified the major obstacles in soft cost reduction, and cooperatively developed stakeholder-centric strategies. This work has enabled us to directly track and report on the growth and effects of recently enacted solar legislation on the industry. This report marks the final in a series of reports examining the effects of Act 236 on the solar economy in SC since 2014.

14 SOLAR ENERGY↗
DOE OSTI2023

Initial Results of PostProcess NDE Using Advanced Techniques

The U.S. Department of Energy, Office of Nuclear Energy Advanced Materials and Manufacturing Technologies Program is developing advanced materials and manufacturing technologies that will enable the safe and economical operation of both the current fleet and the next generation of advanced nuclear reactors. Post-process nondestructive evaluation capabilities are a key enabling technology that will be required to qualify and verify the condition of components produced using advanced materials and manufacturing technologies.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1973

Development of a closed pore insulation material

A closed pore ceramic foam insulation material (CPI) has been developed that offers possibilities for use as a reusable external heat shield for the NASA manned space shuttle. The outstanding characteristics of CPI are: (1) negligible water absorption due to a noninterconnecting network of cells; (2) high emittance at room and elevated temperature; (3) ability to survive at least 10 simulated reentry cycles to 1500 K using radiant heat lamps to simulate the reentry heat fluxes; (4) ability to survive, with no change in properties or appearance, at least 10 simulated plasma arc jet cycles to 1500 K (with the exception of some stress cracks induced either by the unduly severe nature of the initial arc splash heating pulse or by improper mechanical holding of the specimen in the test fixture); (5) strength (flexure); and (6) a low thermal conductivity throughout the temperature range of interest for the space shuttle.

Tobin, A.↗
NASA NTRS1977

Evaluation of aircraft brake materials

A test program was carried out to evaluate several new high-temperature friction materials for use in aircraft disk brakes. A specially built test apparatus utilizing a disk brake and wheel half from a small jet aircraft was used. The apparatus enabled control of brake pressure, velocity and braking time. Tests were run under both constant and variable velocity conditions and covered a kinetic energy range similar to that encountered in aircraft brake service. The materials evaluation showed that two newly developed friction materials show potential for use in aircraft disk brakes. One of the materials is a nickel-based sintered composite, while the other is a molybdenum-based material. Both materials show much lower wear rates than conventional copper-based materials and are better able to withstand the high temperatures encountered during braking. Additional materials improvement is necessary, however, since both materials show a significant negative slope of the friction-velocity curve at low velocities.

Ho, T. L.↗
NASA NTRS1978

Analytical predictions of selenide RTG power degradation

A mathematical model for the performance and degradation analysis of an RTG using the newly developed selenide thermoelectric materials has been developed at JPL. The computerized model is quite comprehensive and enables the accurate detailing of the electrical and thermal effects that take place within the thermocouple under any desired set of operation conditions, including heat input, ambient temperature and load conditions. The paper discusses the logic flow of the computer model and presents the time and temperature dependent results for various degradation mechanisms and rates as they have been established to date.

Noon, E. L.↗
NASA NTRS1983

Elastohydrodynamic lubrication of smooth surfaces

Fully flooded, elastohydrodynamically lubricated contacts are considered. Elastohydrodynamic lubrication (EHL) analysis requires the simultaneous solution of the elastically, viscosity, density, and Reynolds equations. The most important practical aspect of elastohydrodynamic lubrication theory is the determination of the minimum film thickness within the conjunction. The maintenance of a fluid film of adequate magnitude is an essential feature of the correct operation of lubricated machine elements. The results show the influence of contact geometry on minimum film thickness as expressed by the ellipticity parameter and the dimensionless speed, load, and materials parameters. Film thickness equations are developed for materials of high elastic modulus, such as metal, and for materials of low elastic modulus, such as rubber.

Hamrock, B. J.↗
NASA NTRS1986

Characterization of elastomeric materials with application to design

Redesign of the Space Shuttle Solid Booster has necessitated re-evaluation of the material used in the field joint O-ring seals. The viscoelastic characteristics of five candidate materials were determined. The five materials are: two fluorocarbon compounds, two nitrile compounds, and a silicon compound. The materials were tested in a uniaxial compression test to determine the characteristic relaxation functions. These tests were performed at five different temperatures. A master material curve was developed for each material from the experimental data. The results are compared to tensile relaxation tests. Application of these results to the design analysis is discussed in detail.

Bower, Mark V.↗
NASA NTRS1989

Viscoelastic properties of elastomeric materials for O-ring applications

Redesign of the Space Shuttle Solid Rocket Booster necessitated re-evaluation of the material used in the field joint O-ring seals. This research project was established to determine the viscoelastic characteristics of five candidate materials. The five materials are: two fluorocarbon compounds, two nitrile compounds, and a silicon compound. The materials were tested in a uniaxial compression test to determine the characteristic relaxation functions. These tests were performed at five different temperatures. A master material curve was developed for each material from the experimental data. The results of this study are compared to tensile relaxation tests. Application of these results to the design analysis is discussed in detail.

Bower, Mark V.↗
NASA NTRS1990

Scattering from coated structures and antenna pattern control using impedance surfaces, part A/B

The scattering from coated, conducting structures, specifically the coated dihedral corner reflector configuration and the coated strip/plate configuration is examined. The formulation uses impedance-wedge Uniform Theory of Diffraction scattering coefficients to calculate the diffracted fields. A finite-thickness coating is approximated using the impedance boundary condition to arrive at an equivalent impedance for the coating. The formulation of the impedance wedge coefficients is outlined. Far-field, perfectly conducting approximations are discussed. Problems with the present dihedral corner reflector model for certain angles of incidence and observation are discussed along with a potentially rectifying modification. Also, the capacity to measure the electromagnetic properties of lossy materials was developed. The effects of using multiple material coatings on the radiation pattern of the horn antenna were studied. Numerous computations were devoted toward the inverse problem of synthesizing desired radiation patterns using the impedance surfaces. Stabilizing the equivalent sheet impedance using the linear control condition was attempted, and it was found to be a very difficult task.

Balanis, Constantine A.↗
NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗